Page 1 ExpressCard 2000 / ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual February 2020 Document Number: D99875607-91 REGISTERED TO ISO 9001:2015 MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: (562) 546-6400 I Technical Support: (888) 624-8350 www.magtek.com...
Page 2 TrueType® is a trademark of Apple Inc., registered in the United States and other countries. All other system names and product names are the property of their respective owners. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 2 of 356 (D99875607-91)
Page 3 Add steps to lubricate and test embosser hammer pin and Apr 8, 2016 knuckle during preventive maintenance (section 3.12); fix ToC ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 3 of 356 (D99875607-91)
Page 4 MLB handling content from technical bulletin D998200325; Add section 5.16; Add checklists to sections 5.8, 5.19, 5.21; Misc. clarifications and corrections. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 4 of 356 (D99875607-91)
Page 5: Safety
Use materials and supplies specifically designed for MagTek devices. Using unsuitable materials may result in poor performance, and in some cases may be hazardous. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 5 of 356 (D99875607-91)
Page 6: Table Of Contents
Check Firmware Revision Numbers ..................42 3.5.2 Update the Main Logic Board (Controller) Firmware ............43 3.5.3 Update the Image Printer Firmware ................... 45 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 6 of 356 (D99875607-91)
Page 7 How to Remove / Re-install the Cover ..................77 5.3.1 Tools, Materials, and Documents ..................78 5.3.2 Remove............................ 79 5.3.3 Re-install ..........................86 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 7 of 356 (D99875607-91)
Page 8 How to Remove / Re-install the Image Printer Module (EC2000 with ECP2, EC3000)174 5.14.1 Tools, Materials, and Documents ..................175 5.14.2 Remove..........................176 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 8 of 356 (D99875607-91)
Page 9 How to Remove / Re-install the Tipper Module ..............249 5.25.1 Tools, Materials, and Documents ..................251 5.25.2 Remove..........................252 5.25.3 Re-install ..........................258 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 9 of 356 (D99875607-91)
Page 10 Tools, Materials, and Documents ..................314 5.35.2 Remove..........................315 5.35.3 Re-install ..........................316 5.36 How to Remove / Re-install the Touchscreen ..............317 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 10 of 356 (D99875607-91)
Page 11 Known Symptoms and Possible Causes .................. 351 7.1.1 Error message “Card jam at roller station” ..............351 7.1.2 Hopper shuttle does not move ................... 351 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 11 of 356 (D99875607-91)
Page 12 Main Logic Board Diagnostics and Troubleshooting ............352 Appendix A Technical Support ........................ 353 Appendix B Glossary ..........................354 Appendix C Key Loading .......................... 356 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 12 of 356 (D99875607-91)
Page 13: Required Tools, Materials, And Documents
1 ea. Cable tie tool with adjustable tension 1 ea. Multimeter Flex Phillips screwdriver OR 1 ea. Electric screwdriver with flex extension ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 13 of 356 (D99875607-91)
Page 14: Required Materials
1 ea. EC3000 Poster putty, tape, or other adhesive to hold screws on screwdrivers / Ball hex drivers during removal and insertion ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 14 of 356 (D99875607-91)
Page 15: Required Software And Documents
1 - Required Tools, Materials, and Documents Required Software and Documents MagTek recommends loading the following required software and documents on a USB thumb drive or service laptop before visiting the customer site. Part Number Quantity Description D99875600 1 ea.
Page 16: Introduction
D99875730 ExpressCard 2000 / ExpressCard 3000 Replacement Kit List Documents in the service library reference each other frequently and are designed to be used together. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 16 of 356 (D99875607-91)
Page 17: Recommended Preparation For Service Appointments
D998200295 EC3000 Preventive Maintenance Checklist 7) Test the field service laptop to make sure its browser and network connection are functional. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 17 of 356 (D99875607-91)
Page 18: Important Safety Information
For your personal safety, and to prevent damage to the device, disconnect power from the ExpressCard device before you connect or disconnect any cable, electronic board, or assembly. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 18 of 356 (D99875607-91)
Page 19: How To Handle Esd-Sensitive Parts
 Use extra caution when working under climate conditions that increase the potential for ESD, such as cold weather or low humidity. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 19 of 356 (D99875607-91)
Page 20: Introduction To Expresscard Components
“landmarks” visible. In these cases, the caption will generally state the direction the figure can be seen from (for example, “FRONT RIGHT VIEW”). Figure 2-1 – Front/Rear/Left/Right Definition (TOP VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 20 of 356 (D99875607-91)
Page 21: Device Specifications
Some procedures require removing the top access door completely. For removal instructions, see section 5.5 How to Remove / Re-install the Top Access Door. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 21 of 356 (D99875607-91)
Page 22: How To Safely Move Transports By Hand
If you need to move the XY carriage along its tracks, gently pull the carriage to the left side of the device before moving so it won’t catch on the image printer. Figure 2-2 - Move Transports By Pulling Drive Belts ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 22 of 356 (D99875607-91)
Page 23: Hopper Transport Shuttle
(toward the XY transport). Do not try to reverse cards from the image printer into the hopper shuttle. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 23 of 356 (D99875607-91)
Page 24: How To Use Maintenance Functions On The Touchscreen
ExpressCard’s sensors, or use the page to move the MCP Commands various parts of the device individually rather than as part of a standard sequence. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 24 of 356 (D99875607-91)
Page 25: How To Use The Mcp Commands Page
Top Cartridge Load Only if testing ExpressCard with Front Indenter installed: Front (white) indent cartridge moves back into embosser Indenter Move ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 25 of 356 (D99875607-91)
Page 26 Card goes into Card Rejection Bin. Exit Eject Exit Transport rolls card to exit ramp, ramp fan turns on briefly. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 26 of 356 (D99875607-91)
Page 27: How To Use The Sensor Utility Page
/ indent ribbon sensors included. Figure 2-4 - Sensor Utility Page (EC2000) Figure 2-5 - Sensor Utility Page for EC3000 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 27 of 356 (D99875607-91)
Page 28 Blocked when the hopper shuttle is parked at the rear right corner of the device. Exception Feed Blocked when a card just enters the manual feed slot. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 28 of 356 (D99875607-91)
Page 29 Blocked when a card just reaches the rollers on the exit ramp. Tipper Exit Blocked when a card just reaches the end of the exit ramp. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 29 of 356 (D99875607-91)
Page 30 The tipper foil sensor, mounted on the front top center of the Exit Transport.  The indent cartridge ribbon sensor, mounted on the front surface of the X Transport on the left. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 30 of 356 (D99875607-91)
Page 31: How To Use The Embosser Utility Page
2) Set the number of steps you want the embosser wheel to take (see section 2.9.3.1 About the Embosser Utility Page) and press the button. Wheel Motor Move 3) Repeat the moves as necessary to complete the test. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 31 of 356 (D99875607-91)
Page 32: How To Move The Embosser Cams (Hammers)
The page also provides a Reset button that will reset all tine settings to factory defaults. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 32 of 356 (D99875607-91)
Page 33 Save All 7) Press the button to return to the page. Status Status ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 33 of 356 (D99875607-91)
Page 34: How To Use The Character Mapping Page
9) Test your changes by creating a sample card or an embosser tuning card. To add a new character to an embosser wheel tine, follow these steps: ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 34 of 356 (D99875607-91)
Page 35 12) Repeat the above steps for any additional characters you need to add. 13) Test your changes by creating a sample card or an embosser tuning card. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 35 of 356 (D99875607-91)
Page 36: Preventive Maintenance Procedure (Ec2000)
The following page shows a flowchart that gives a brief overview of the preventive maintenance procedure. It should only be used as a guide, not as a substitute for following the detailed steps provided. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 36 of 356 (D99875607-91)
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: Prepare The Device For Preventive Maintenance
Manual for detailed instructions) and set it aside in a secure location, or offer it to the customer for temporary storage or secure disposal. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 38 of 356 (D99875607-91)
Page 39 Feed the cleaning card partly into the right side of the exit transport and press the Exit Reject button. Push inward to keep the card from being pushed out until the rollers stop moving. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 39 of 356 (D99875607-91)
Page 40 6) Re-install the tipper foil cartridge with the original tipper foil roll, or obtain and install a new one from the customer. 7) Re-install hoppers 1 and 2. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 40 of 356 (D99875607-91)
Page 41: Update The Software
3 - Preventive Maintenance Procedure (EC2000) Update the Software If MagTek Support Services has supplied .CAB files to apply EC2000 software patches, follow these steps to install them: 1) Use the Ethernet cable to connect the service laptop to EC2000. If necessary, you may instead use the customer’s instant issuance workstation, provided it has Microsoft Internet Explorer and a USB...
Page 42: Update The Firmware
3 - Preventive Maintenance Procedure (EC2000) Update the Firmware If MagTek Support Services has supplied .CAB files to apply firmware patches, follow the steps in this section to determine whether the firmware needs to be updated, and to update it if necessary.
Page 43: Update The Main Logic Board (Controller) Firmware
3) Press the Download button to download the .hex file to the controller. The system will report “Loading the firmware. Please wait….” ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 43 of 356 (D99875607-91)
Page 44 5) After the firmware update is complete, the device will make sounds as the MLB resets. Wait until the sounds stop and the touchscreen reports “Finished loading the firmware.” ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 44 of 356 (D99875607-91)
Page 45: Update The Image Printer Firmware
.hex file appropriate to the revision of the image printer firmware you want to install, before pressing the button. Download ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 45 of 356 (D99875607-91)
Page 46: Service The Hopper Module
2) Only if the hopper transport rods are dirty, wipe off the dirt with a soft, lint-free cloth. 3) Check the hopper transport drive belt for signs of damage. If it is damaged, contact MagTek Support Services for a replacement.
Page 47: Service The Xy Transport Module
1) If there is dirt, dust, or debris on the XY transport rods, wipe it off using a soft, lint-free cloth. 2) Check the XY transport drive belt for any signs of damage. If it is damaged, contact MagTek Support Services for a replacement.
Page 48 Use the drive belt to move the XY transport to the front of the device, then to the rear again to spread the Tri-Flow along the length of the shaft (see section 2.8 How to Safely Move Transports By Hand). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 48 of 356 (D99875607-91)
Page 49 If you have applied too much Tri-Flow to the shaft, some may drip off the shaft. If this happens, dab off the excess with a clean, lint free cloth. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 49 of 356 (D99875607-91)
Page 50: Service The Exit Transport Module
15 minutes. You may be able to use compressed air to cool it more quickly. 5) Power down the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 50 of 356 (D99875607-91)
Page 51: Clean Inside The Device
6) Use compressed air to clean out the electronics in the bottom between the side access doors, with special attention paid to the power supply in the rear left corner. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 51 of 356 (D99875607-91)
Page 52: Service The Image Printer Module
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 ExpressCard 2000 Installation and Operation Manual for cleaning information, and section 5.11 How to Remove / Re-install the Image Printer Card Cleaning Roller (EC2000 with ECP1) for replacement steps.
Page 53: Service The Embosser Module
EC2000’s cover and other modules installed, it is best to inspect the cones with an inspection mirror. Section 3.12.2 provides further detail. Figure 3-9 - Embosser Hammer and Character (FRONT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 53 of 356 (D99875607-91)
Page 54: How To Service The Embosser Module
33070184 TYPE,GOTHIC,SPECIAL CHARACTERS,EMBOSS PUNCH f) 33070582 TYPE, TURKISH EMBOSS PUNCH g) 33070608 TYPE, FRONT INDENT BANK ID NUMBER h) 33070074 ANVIL,FRONT INDENT ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 54 of 356 (D99875607-91)
Page 55 10) Add 2 drops of Teflon lubricant to the left and right sides of the shaft that holds the top embosser knuckle, between the sides of the knuckle and the rocker arm. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 55 of 356 (D99875607-91)
Page 56 13) Add 2 drops of lubricant between bottom punch hammer and bottom hammer follower. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 56 of 356 (D99875607-91)
Page 57 The knuckle should not rotate from its initial orientation. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 57 of 356 (D99875607-91)
Page 58: Service The Electronics
8) Check image print quality and embosser alignment, and adjust components as necessary using the information in section 6 Adjustments. 9) Fill out the checklist included with the preventive maintenance kit, and return it to MagTek. Ensure any unused materials from the kit are personally handed off to a branch representative –...
Page 59: Preventive Maintenance Procedure (Ec3000)
The following page shows a flowchart that gives a brief overview of the preventive maintenance procedure. It should only be used as a guide, not as a substitute for following the detailed steps provided. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 59 of 356 (D99875607-91)
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: Prepare The Device For Preventive Maintenance
To prepare the device for service, follow these steps in accordance with standard safety practices: 1) Check the labels on the top access door and on the rear of the device to make sure you are servicing an ExpressCard 3000. If you are servicing an ExpressCard 2000, the maintenance procedure is slightly different.
Page 62: Update The Software
4 - Preventive Maintenance Procedure (EC3000) Update the Software If MagTek Support Services has supplied .CAB files to apply ExpressCard software patches, follow these steps to install them: 1) Use the Ethernet cable to connect the service laptop to the ExpressCard. If necessary, you may instead use the customer’s instant issuance workstation, provided it has Microsoft Internet Explorer...
Page 63: Update The Firmware
4 - Preventive Maintenance Procedure (EC3000) Update the Firmware If MagTek Support Services has supplied .CAB files to apply firmware patches, follow the steps in this section to determine whether the firmware needs to be updated, and to update it if necessary.
Page 64: Update The Main Logic Board (Controller) Firmware
3) Press the Download button to download the .hex file to the controller. The system will report Loading the firmware. Please wait… ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 64 of 356 (D99875607-91)
Page 65 5) After the firmware update is complete, the device will make sounds while the MLB resets. Wait until the sounds stop and the touchscreen reports Finished loading the firmware. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 65 of 356 (D99875607-91)
Page 66: Update The Image Printer Firmware
.hex file appropriate to the revision of the image printer firmware you want to install, before pressing the Download button. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 66 of 356 (D99875607-91)
Page 67: Service The Hopper Module
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 the device. 3) Check the XY transport drive belt for any signs of damage. If it is damaged, contact MagTek Support Services for a replacement.
Page 68: Clean Inside The Device
4) Check handoff from image printer to XY transport. Adjust if needed (see section 6.5.2 How to Calibrate Printer to XY Transport Handoff. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 68 of 356 (D99875607-91)
Page 69: Service The Embosser Module
EC3000’s cover and other modules installed, it is best to inspect the cones with an inspection mirror. Section 4.12.2 provides further detail. Figure 4-1 - Embosser Hammer and Character (FRONT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 69 of 356 (D99875607-91)
Page 70: How To Service The Embosser Module
33070184 TYPE,GOTHIC,SPECIAL CHARACTERS,EMBOSS PUNCH f) 33070582 TYPE, TURKISH EMBOSS PUNCH g) 33070608 TYPE, FRONT INDENT BANK ID NUMBER h) 33070074 ANVIL,FRONT INDENT ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 70 of 356 (D99875607-91)
Page 71 10) Add 2 drops of Teflon lubricant to the left and right sides of the shaft that holds the top embosser knuckle, between the sides of the knuckle and the rocker arm. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 71 of 356 (D99875607-91)
Page 72 13) Add 2 drops of lubricant between bottom punch hammer and bottom hammer follower. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 72 of 356 (D99875607-91)
Page 73 The knuckle should not rotate from its initial orientation. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 73 of 356 (D99875607-91)
Page 74: Service The Electronics
8) Check image print quality and embosser alignment, and adjust components as necessary using the information in section 6 Adjustments. 9) Fill out the checklist included with the preventive maintenance kit, and return it to MagTek. Ensure any unused materials from the kit are personally handed off to a branch representative –...
Page 75: Removal And Re-Installation
Depending on the installation location, you may need to move the device to a service location. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 75 of 356 (D99875607-91)
Page 76: How To Retrieve Dropped Screws And Other Hardware
If lifting one side does not work, try another. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 76 of 356 (D99875607-91)
Page 77: How To Remove / Re-Install The Cover
Some service procedures require removing the device’s cover to give unobstructed access to certain components. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 77 of 356 (D99875607-91)
Page 78: Tools, Materials, And Documents
1 ea. EC2000, EC3000 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 78 of 356 (D99875607-91)
Page 79: Remove
Figure 5-3 - Bezel LED Signal Cable (REAR VIEW) 7) Disconnect the Exception Card Entry sensor cable in the front right corner of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 79 of 356 (D99875607-91)
Page 80 9) Disconnect the touchscreen VGA video cable and the power cable from the rear of the touchscreen. If there is any silicone adhesive on the cables or their connections, remove it completely. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 80 of 356 (D99875607-91)
Page 81 Figure 5-7 - Touchscreen Power and VGA Cables (REAR VIEW) 11) Disconnect the Top Case Open sensor cable in the rear left corner of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 81 of 356 (D99875607-91)
Page 82 It can be found in the upper rear right of the device behind hopper 1, as shown in Figure 5-9. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 82 of 356 (D99875607-91)
Page 83 Otherwise, the front two screws may be easier to remove with the No. 1 Phillips screwdriver. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 83 of 356 (D99875607-91)
Page 84 Figure 5-13 - Plastic Fastener Plates (LEFT VIEW) 15) Locate the two screws that secure the front of the cover next to the tipper. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 84 of 356 (D99875607-91)
Page 85 Figure 5-15 - Removing the Cover (FRONT LEFT VIEW) 19) Perform any additional replacement or maintenance steps. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 85 of 356 (D99875607-91)
Page 86: Re-Install
3) Move the cover slightly to the right and rest its right side on the tabletop next to the device; this will give you easier access to the connectors around the hopper module. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 86 of 356 (D99875607-91)
Page 87 “captures” it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 87 of 356 (D99875607-91)
Page 88 See Figure 5-20 for reference. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 88 of 356 (D99875607-91)
Page 89 Do not push the plates too hard toward the ceiling, or you may pop the screw out of its hole. e) Screw both screws partway into the plate before tightening them all the way. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 89 of 356 (D99875607-91)
Page 90 Status c) Test the electronic latches by testing the remote unlock function. 22) If the device does not power on or function properly, contact MagTek Support Services for assistance (see Appendix A Technical Support). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual...
Page 91: How To Remove / Re-Install The Right Side Cover
Flashlight or equivalent 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 91 of 356 (D99875607-91)
Page 92: Remove
7) Lay the cover on a flat surface and remove the three screws that attach the right side cover to the whole cover. Figure 5-23 - Right Side Cover Screws 8) Remove the right side cover. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 92 of 356 (D99875607-91)
Page 93: Re-Install
Status c) Test the electronic latches by testing the remote unlock function. 8) If the device does not power on or function properly, contact MagTek Support Services for assistance (see Appendix A Technical Support). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual...
Page 94: How To Remove / Re-Install The Top Access Door
Some service procedures require removing the top access door to give unobstructed access to certain components. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 94 of 356 (D99875607-91)
Page 95: Tools, Materials, And Documents
Flashlight or equivalent 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 95 of 356 (D99875607-91)
Page 96: Remove
Figure 5-25 - Pulling the Left Side of the Top Access Door Out of Its Track (FRONT VIEW) 8) Repeat the process, pulling it to the left and slightly upward, to free it from its right track. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 96 of 356 (D99875607-91)
Page 97 14) Remove the top access door and set it aside with the two screws and washers (if necessary, move the XY transport out of the way per section 2.8 How to Safely Move Transports By Hand). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 97 of 356 (D99875607-91)
Page 98: Re-Install
To re-install the top access door, reverse the steps for removing it. Be careful not to lose the door’s bushings, which are not secured to the cover or to the top access door’s hinges. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 98 of 356 (D99875607-91)
Page 99: How To Remove / Re-Install The Top Access Door Right Latch
Its solenoid is connected to the electronics in the device and allows the user to open the top access door using the touchscreen. Figure 5-29 –Top Access Door Right Latch (LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 99 of 356 (D99875607-91)
Page 100: Tools, Materials, And Documents
Flashlight or equivalent 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 100 of 356 (D99875607-91)
Page 101: Remove
6) Trace the cable from the latch solenoid to its connector in the front right corner of the case, just below the hopper plate. Pull gently upward on the cable to bring its connector within easy reach. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 101 of 356 (D99875607-91)
Page 102 Support the solenoid and remove the third/final screw and lock washer. Set all parts aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 102 of 356 (D99875607-91)
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: Re-Install
4) Trace the connected cable to below the hopper plate. Pull gently downward on the cable to take up the slack from above, then tuck the cable below the other cables below the hopper plate as shown. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 104 of 356 (D99875607-91)
Page 105 Unlock Top Door 11) Create some sample cards and make sure the hopper shuttle does not catch on the cables below it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 105 of 356 (D99875607-91)
Page 106: How To Remove / Re-Install The Side Access Doors
Flashlight or equivalent 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 106 of 356 (D99875607-91)
Page 107: Remove
7) Lower the side access door to free its bottom tabs from the cover, remove it, and set it aside. Figure 5-32 - Removing the Left Side Access Door (FRONT LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 107 of 356 (D99875607-91)
Page 108: Re-Install
6) Tug on the side access door to make sure it is secure. 7) Remove any props under the device’s feet, and return it to its original location. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 108 of 356 (D99875607-91)
Page 109: How To Remove / Re-Install The Hopper Module
Approximate time to remove: 30 minutes plus any sub-procedures Approximate time to re-install: 30 minutes plus any sub-procedures Figure 5-33 - Hopper Module (FRONT RIGHT VIEW FROM ABOVE) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 109 of 356 (D99875607-91)
Page 110 It is mounted to the top deck plate of the device along the right side. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 110 of 356 (D99875607-91)
Page 111: Tools, Materials, And Documents
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Page 112: Remove
5) Carefully lift the hopper deck plate off the hopper module, turn it over so you can see printed circuit board on the bottom, and locate the two sensor cables connected near the rear of the hopper module. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 112 of 356 (D99875607-91)
Page 113 8) Pull on the hopper shuttle drive belt to move the hopper shuttle toward the rear of the device, past the connectors on the top deck plate. Do not pull directly on the hopper shuttle or you may damage ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 113 of 356 (D99875607-91)
Page 114 11) Slip the hopper shuttle belt completely off the pulley near the rear of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 114 of 356 (D99875607-91)
Page 115 HOPPER SHUTTLE EXC HOME SENSOR J4 EXC HOME SENS circuit board. Unplug the cable from the circuit board. HOPPER SHUTTLE ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 115 of 356 (D99875607-91)
Page 116 HOPPER SHUTTLE EXC HOME SENSOR corner of the device’s case, and route it outside the case to keep it out of the way. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 116 of 356 (D99875607-91)
Page 117 18) Disconnect the flex cable from the hopper shuttle. It may require both hands to apply enough force, because the hopper shuttle obstructs direct access. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 117 of 356 (D99875607-91)
Page 118 20) Use your fingers to rub all foam tape residue off the connector end of the flex cable. 21) Gently push the hopper shuttle toward the front of the device, past the connectors on the top deck plate. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 118 of 356 (D99875607-91)
Page 119 HOPPER SHUTTLE 23) Trace the cable back to the hopper module and cut any cable HOPPER SHUTTLE HOME SENSOR ties holding it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 119 of 356 (D99875607-91)
Page 120 25) Gently push the hopper shuttle to the middle of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 120 of 356 (D99875607-91)
Page 121 Set the hopper module aside. 28) If you are removing the hopper transport gearbox, locate it at the rear of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 121 of 356 (D99875607-91)
Page 122 The screw nearer the front of the device is beneath a bundle of cables, which you will have to move out of the way. 30) Disconnect the gearbox cable from the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 122 of 356 (D99875607-91)
Page 123 31) Remove the hopper gearbox and screws and set them aside. 32) Remove the screws and washers from the hopper gearbox for later use. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 123 of 356 (D99875607-91)
Page 124: Re-Install
2) Locate the cutout in the top deck plate near the rear of the device where the hopper gearbox will be installed. 3) Locate the lip of the image printer base plate that overlaps the cutout. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 124 of 356 (D99875607-91)
Page 125 5) Make sure the thick light-colored cable is behind and below the gearbox, and use the 5/32” hex wrench tighten the two screws that hold the gearbox to the top deck plate. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 125 of 356 (D99875607-91)
Page 126 Make sure the hopper shuttle pusher is retracted and clear of the hopper deck plate. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 126 of 356 (D99875607-91)
Page 127 10) Use one hand to lift the hopper module into the device, freeing up your other hand to move the cables and drive belt and any other obstructions out of the way. Focus on installing the rear side first. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 127 of 356 (D99875607-91)
Page 128 12) Carefully lower the front side of the hopper module to the top deck plate and line it up with the screw holes. Use your free hand to make sure the module doesn’t pinch any cables or the drive belt. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 128 of 356 (D99875607-91)
Page 129 14) Use the 5/32” hex wrench to insert and tighten the four screws and washers that secure the hopper module to the top deck plate. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 129 of 356 (D99875607-91)
Page 130 17) Route the cable along the rear wall of the device and tuck it below the shielding around the image printer, then route the free end toward the front of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 130 of 356 (D99875607-91)
Page 131 HOPPER SHUTTLE HOME cable to the bundle of cables. Use wire cutters or a cable tie tool to trim the ties. SENSOR ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 131 of 356 (D99875607-91)
Page 132 22) Route the cable underneath the other cables that run HOPPER SHUTTLE EXC HOME SENSOR along the right side of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 132 of 356 (D99875607-91)
Page 133 24) Plug the cable into the HOPPER SHUTTLE EXC HOME SENSOR J4 EXC HOME SENS connector on the circuit board. HOPPER SHUTTLE ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 133 of 356 (D99875607-91)
Page 134 HOPPER SHUTTLE EXC HOME SENSOR cable into the cable clip along the right wall of the device, and take up any slack along its length. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 134 of 356 (D99875607-91)
Page 135 During testing, the belt should not slip or make grinding sounds. If it does, the tension may need to be re-adjusted. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 135 of 356 (D99875607-91)
Page 136 7 and before it rotates to the manual feed slot. Do not pull on the hopper shuttle directly or you may damage it. 30) Remove the protective backing from the foam tape on the hopper shuttle motor. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 136 of 356 (D99875607-91)
Page 137 32) Pull on the hopper shuttle drive belt to move the hopper shuttle all the way to the front of the device, until it rotates completely into the manual feed position and stops. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 137 of 356 (D99875607-91)
Page 138 34) While holding the flex cable taut, use your left hand to press the flex cable straight back onto the double-stick tape. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 138 of 356 (D99875607-91)
Page 139 36) Pull on the hopper shuttle drive belt to move the hopper shuttle all the way to the rear of the device until it stops. Do not pull on the hopper shuttle directly or you may damage it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 139 of 356 (D99875607-91)
Page 140 Do not pull on the hopper shuttle directly or you may damage it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 140 of 356 (D99875607-91)
Page 141 41) Use the 5/64” hex wrench to re-install 5 ea. screw 46500187 that hold the hopper deck plate to the hopper module. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 141 of 356 (D99875607-91)
Page 142 They should be routed down toward the rear of the device and out of the path of the hopper shuttle. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 142 of 356 (D99875607-91)
Page 143 53) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 143 of 356 (D99875607-91)
Page 144: How To Remove / Re-Install The Hopper Module Flex Cable
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Page 145: Remove
4) Use the 5/64” hex wrench to remove the five screws that secure the hopper deck plate to the hopper module. Figure 5-36 - Remove the Hopper Deck Plate Screws (FRONT LEFT VIEW FROM ABOVE) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 145 of 356 (D99875607-91)
Page 146 8) Disconnect the flex cable from the hopper shuttle, and carefully pull it free from the small pad of double-sided foam tape just next to the plug (see Figure 5-39). Discard the foam tape. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 146 of 356 (D99875607-91)
Page 147 (see Figure 5-40). It should HOPPER SHUTTLE require very little force. If it sticks, make sure the connector is completely unlocked. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 147 of 356 (D99875607-91)
Page 148 14) Use your fingers to completely rub off all foam tape residue from the cover and from the hopper shuttle motor until both surfaces are clean. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 148 of 356 (D99875607-91)
Page 149 Figure 5-43 - Clean Off Foam Tape from Hopper shuttle Motor (RIGHT VIEW) 15) Use the alcohol swab to clean both surfaces to remove any oil left by your hands. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 149 of 356 (D99875607-91)
Page 150: Re-Install
4) Push the outer edge of the connector inward to lock it. Pull gently on the flex cable to make sure it is locked. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 150 of 356 (D99875607-91)
Page 151 7) Stick 3/8” of double-stick tape to the hopper motor, vertically centered on the flex cable connector, as shown. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 151 of 356 (D99875607-91)
Page 152 10) Gently pull the long loop of the flex cable straight toward the rear of the device, away from the hopper shuttle. This puts the flex cable in the right position to stick it to the motor. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 152 of 356 (D99875607-91)
Page 153 15) Test the new flex cable by pulling on the drive belt to move the hopper shuttle along the full range from front to back. Do not pull directly on the hopper shuttle or you may damage it. Make sure ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 153 of 356 (D99875607-91)
Page 154 23) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 154 of 356 (D99875607-91)
Page 155: How To Remove / Re-Install The Image Printer Module (Ec2000 With Ecp1)
XY transport. Figure 5-48 - Removing / Re-installing the Image Printer (FRONT RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 155 of 356 (D99875607-91)
Page 156: Tools, Materials, And Documents
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Page 157: Remove
Find connector J31 on the circuit board, and unplug the black insulated cable from it (see Figure 5-50 and Figure 5-53). This is the image printer USB cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 157 of 356 (D99875607-91)
Page 158 10) Use both hands to carefully lift the image printer out of the device, making sure no cables catch on it as you remove it. Set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 158 of 356 (D99875607-91)
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: Re-Install
(see Figure 5-48). 5) Re-connect the power cable, re-connect the card exit sensor, and re-connect the USB cable to J31. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 160 of 356 (D99875607-91)
Page 161 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 image printer ribbon following the steps provided in D99875600 ExpressCard 2000 Installation and Operation Manual.
Page 162: How To Remove / Re-Install The Image Printer Card Cleaning Roller (Ec2000 With Ecp1)
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 D99875600 ExpressCard 2000 Installation and Operation Manual). 4) Remove the card cleaning roller and discard it (see Figure 5-55).
Page 163: How To Remove / Re-Install The Image Print Head (Ec2000 With Ecp1)
Before replacing the print head, contact MagTek Support Services or your MagTek reseller to check whether replacement is advisable and to order the part. During the print head’s warranty period, MagTek will provide free exchanges for defective print heads, provided: ...
Page 164 Guide the whole print head assembly out of the groove that locks it in place. 9) Tilt the head carefully, and gently disconnect the cable without using force on the mechanism. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 164 of 356 (D99875607-91)
Page 165 21) Close the EC2000 top access door. 22) Test your changes by creating a sample card or an embosser tuning card. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 165 of 356 (D99875607-91)
Page 166: How To Remove / Re-Install The Image Printer Top Door Cover (Ec2000 With Ecp1)
ASSEMBLY, FIELD SERVICE KIT, SPARE PARTS STARTER, 33011009 1 ea. EC2000, EC3000 1 ea. Flashlight or equivalent 1 ea. Pen or pencil 1 ea. Paper and clipboard ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 166 of 356 (D99875607-91)
Page 167: Remove
4) If this is a warranty replacement, evaluate the customer’s installation and use of the device to ensure they have not voided the warranty. Contact MagTek Support Services if you have doubts that the conditions of the warranty are not met.
Page 168 10) Examine the replacement release button to become familiar with the two hooks that hold it onto the sheet metal of the image printer case. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 168 of 356 (D99875607-91)
Page 169 13) Repeat the same process for the other hook and remove the button. Gently lower the lid. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 169 of 356 (D99875607-91)
Page 170: Re-Install
Make sure the sheet metal is not bent. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 170 of 356 (D99875607-91)
Page 171 7) Hold the lid cover in place while you gently lower the lid. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 171 of 356 (D99875607-91)
Page 172 13) Re-connect the power cable, network cable, and any security hardware. 14) Close EC2000’s top access door. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 172 of 356 (D99875607-91)
Page 173 After the device is connected to QwickCards.com, request that the customer create a card using QwickCards.com to make sure the connection and configuration are working properly. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 173 of 356 (D99875607-91)
Page 174: How To Remove / Re-Install The Image Printer Module (Ec2000 With Ecp2, Ec3000)174
XY transport. Figure 5-58 - Removing / Re-installing the Image Printer (FRONT RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 174 of 356 (D99875607-91)
Page 175: Tools, Materials, And Documents
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Page 176: Remove
7) Use the 5/32” hex wrench to remove the 2 screws and washers that hold the right side of the image printer onto the top deck plate, and set them aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 176 of 356 (D99875607-91)
Page 177 Look for the screw from the top, just to the left of the image printer power button. 9) On the rear right side of the image printer, disconnect the power cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 177 of 356 (D99875607-91)
Page 178 CABLE and disconnect it (Figure 5-60). If the right XY transport rail is in the way, you may use two pairs of needle nose pliers to disconnect and reconnect it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 178 of 356 (D99875607-91)
Page 179 13) Use both hands to carefully lift the image printer out of the device, making sure no cables catch on it as you remove it. Set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 179 of 356 (D99875607-91)
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: Re-Install
Leave the image printer loose / unfastened so you can easily move it to access cables and connectors in the following steps. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 181 of 356 (D99875607-91)
Page 182 8) Re-connect the image printer sensor cable, then re-route it below the front lip of the image printer behind the other cables. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 182 of 356 (D99875607-91)
Page 183 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 183 of 356 (D99875607-91)
Page 184 14) Carefully slide the XY transport toward the front and rear of the device several times to make sure it will not touch the image printer when moving. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 184 of 356 (D99875607-91)
Page 185 18) Connect a USB keyboard to a spare USB port on the embedded PC. 19) Re-connect the power cable to the back right of the image printer. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 185 of 356 (D99875607-91)
Page 186 35) Configure the image printer ribbon following the steps provided in D998200281 ExpressCard 3000 Installation and Operation Manual. This is very important because it also re-initializes ExpressCard’s connection to the image printer. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 186 of 356 (D99875607-91)
Page 187 38) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 187 of 356 (D99875607-91)
Page 188: How To Upgrade The Image Printer Module From Ecp1 To Ecp2
At this time, there is no upgrade path to replace the image printer model referred to as “ECP1” with the printer model referred to as “ECP2.” Reserved for future use. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 188 of 356 (D99875607-91)
Page 189: How To Remove / Re-Install The Image Printer Card Cleaning Roller (Ec2000 With Ecp2, Ec3000)
If the sample does not look correct (e.g., images do not print correctly), contact MagTek Support Services for assistance. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 189 of 356 (D99875607-91)
Page 190: How To Remove / Re-Install The Image Print Head (Ec2000 With Ecp2, Ec3000)
Before replacing the print head, contact MagTek Support Services or your MagTek reseller to check whether replacement is advisable and to order the part. During the print head’s warranty period, MagTek will provide free exchanges for defective print heads, provided: ...
Page 191: Tools, Materials, And Documents
Tools, materials, and documents required for sub-procedures Suggested 1 ea. Digital camera or smartphone with camera 1 ea. Flashlight or equivalent ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 191 of 356 (D99875607-91)
Page 192: Remove
4) Open the EC3000 top access door (see D998200281 ExpressCard 3000 Installation and Operation Manual for details). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 192 of 356 (D99875607-91)
Page 193 8) Look at the print head from the side and find the hooks that hold the print head in place. Note that the head is spring loaded such that gentle pressure inward moves it far enough inward to unhook from both sides. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 193 of 356 (D99875607-91)
Page 194 10) Gently disconnect the print head cable. This part is fragile: Do not use force to connect the cable. 11) Remove the print head and set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 194 of 356 (D99875607-91)
Page 195: Re-Install
4) Press gently on each side of the connector to make sure it is firmly connected. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 195 of 356 (D99875607-91)
Page 196 12) Close the EC3000 top access door. 13) Test your changes by creating a sample card or an embosser tuning card. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 196 of 356 (D99875607-91)
Page 197: How To Remove / Re-Install The Image Printer Top Door Cover (Ec3000)
5 - Removal and Re-installation 5.18 How to Remove / Re-install the Image Printer Top Door Cover (EC3000) Reserved for future use. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 197 of 356 (D99875607-91)
Page 198: How To Remove / Re-Install The Xy Transport Module
Approximate time to re-install: 15 minutes plus any sub-procedures Figure 5-64 - Removing and Re-Installing the XY Transport Module (FRONT RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 198 of 356 (D99875607-91)
Page 199 The XY transport receives cards from the image printer module and moves them to the embosser module, then to the exit transport module. It is located along the left side of the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 199 of 356 (D99875607-91)
Page 200: Tools, Materials, And Documents
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Page 201: Remove
5) Move the XY transport toward the front of the device (see section 2.8 How to Safely Move Transports By Hand). 6) Snap open the XY transport ribbon cable clamp between the rails as shown in Figure 5-66. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 201 of 356 (D99875607-91)
Page 202 . Follow these SPARE #2 TOP DECK RECEPTACLE SPARE #2 steps to free it from the device: ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 202 of 356 (D99875607-91)
Page 203 Disconnect the two sides. d) Follow the XY side of the sensor cable to the left wall and unclip it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 203 of 356 (D99875607-91)
Page 204 14) Use both hands on the rails to carefully lift the XY transport module out of the device, making sure no cables catch on any other modules, and set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 204 of 356 (D99875607-91)
Page 205: Re-Install
13) Re-attach the top access door by reversing the steps you used to lean it back. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 205 of 356 (D99875607-91)
Page 206 Samples functions properly and the sample looks correct. 16) If the device does not power on or function properly, contact MagTek Support Services for assistance (see Appendix A Technical Support). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual...
Page 207: How To Remove / Re-Install The Xy Transport Ribbon Cable
For instructions on removing and re-installing the entire XY transport module, see section 5.19 How to Remove / Re-install the XY Transport. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 207 of 356 (D99875607-91)
Page 208: Tools, Materials, And Documents
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Page 209: Remove
Lift both clips firmly toward the ceiling to unlock and eject the cable from the circuit board, then disconnect the ribbon cable. See Figure 5-72. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 209 of 356 (D99875607-91)
Page 210 6) Disconnect the ribbon cable from the circuit board on the top deck plate, and set the cable aside. 7) If there is adhesive on any of the connectors, peel or gently scrape it off and discard it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 210 of 356 (D99875607-91)
Page 211: Re-Install
(see Figure 5-74). Figure 5-74 - Locking XY Transport Ribbon Cable In Place (TOP VIEW FROM LEFT) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 211 of 356 (D99875607-91)
Page 212 Figure 5-76 - XY Transport Ribbon Cable Installed (TOP VIEW FROM LEFT) 5) Push the retaining clips down toward the printed circuit board and pinch to lock them in place. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 212 of 356 (D99875607-91)
Page 213 12) On the touchscreen, navigate to Menu > Samples , create a sample card, and make sure the device functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 213 of 356 (D99875607-91)
Page 214: How To Remove / Re-Install The Embosser Module
The embosser module, located at the front left corner of the device, punches raised and indented characters into cards as they are held by the XY transport. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 214 of 356 (D99875607-91)
Page 215: Tools, Materials, And Documents
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Page 216: Unpack
4) Carefully lift the embosser out of the box as shown in Figure 5-80. Turn it upside down so the embosser is facing up, and set it on a sturdy work surface. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 216 of 356 (D99875607-91)
Page 217 (see Figure 5-82). Set the hardware aside in the bottom of the box. Figure 5-82 – Nuts and Bolts Holding Indenter to Embosser ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 217 of 356 (D99875607-91)
Page 218: Remove
9) Re-route the embosser cable so the connector rests on top of the XY transport rails, as shown in Figure 5-84. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 218 of 356 (D99875607-91)
Page 219 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 219 of 356 (D99875607-91)
Page 220 13) Use both hands to lift the embosser and indenter modules out of the device, making sure the embosser cable does not catch on anything on the way out. Set the modules aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 220 of 356 (D99875607-91)
Page 221: Re-Install
Figure 5-88 - Embosser Base Keys In Top Deck Plate (TOP RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 221 of 356 (D99875607-91)
Page 222 Wheel Mapping b) Enter password and press the key to open the second password 4567890 Wheel Mapping page. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 222 of 356 (D99875607-91)
Page 223 Print d) Inspect the card to make sure the embosser is working as expected. 19) If the device does not power on or function properly, contact MagTek Support Services for assistance (see Appendix A Technical Support). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual...
Page 224: Pack
5 - Removal and Re-installation 5.21.5 Pack To pack the embosser and tools in the replacement packaging for return to MagTek, reverse the unpacking steps from the beginning of this section: 1) Use the pliers 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.
Page 225 4) Pack the tools into the cardboard accessory box and seal it. 5) Return the embosser and the tools to MagTek. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 225 of 356 (D99875607-91)
Page 226: How To Remove / Re-Install Embosser Fonts
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Page 227: Remove And Re-Install
6) Notify the ExpressCard’s software that the character has moved. For detailed instructions, see section 2.9.4 How to Use the Character Mapping Page. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 227 of 356 (D99875607-91)
Page 228: How To Remove / Re-Install The Exit Transport Module
Approximate time to remove: 30 minutes plus any sub-procedures Approximate time to re-install: 30 minutes plus any sub-procedures Figure 5-95 - Exit Transport Module (FRONT RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 228 of 356 (D99875607-91)
Page 229 (DI) for later validation that the card is genuine and that its encoded data has not been altered. The exit transport is attached to the center of the device’s top deck plate. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 229 of 356 (D99875607-91)
Page 230: Tools, Materials, And Documents
/ hex drivers during removal / re-insertion 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 230 of 356 (D99875607-91)
Page 231: Remove
Follow its cable down the front left corner of the module to a cable clip on the top deck. d) Unclip the cable and follow it further to the connector. e) Disconnect the cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 231 of 356 (D99875607-91)
Page 232 Pull the exit transport slightly forward (or out) and cut the cable tie that holds the MSR cable to the main cable on the bottom back of the exit transport’s base. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 232 of 356 (D99875607-91)
Page 233 8) Carefully lift the exit transport module out of the device, making sure no wires catch on it, and set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 233 of 356 (D99875607-91)
Page 234: Re-Install
Figure 5-98 - Tipper Foil Sensor On Exit Transport Module 2) Make sure the embosser wheel is rotated so the empty tines are facing the exit transport and tipper. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 234 of 356 (D99875607-91)
Page 235 14) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 235 of 356 (D99875607-91)
Page 236: How To Remove / Re-Install The Combined Tipper Module / Exit Transport Module
Approximate time to re-install: 30 minutes plus any sub-procedures Figure 5-99 - Combination Tipper Module / Exit Transport Module (FRONT LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 236 of 356 (D99875607-91)
Page 237 ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 237 of 356 (D99875607-91)
Page 238: Tools, Materials, And Documents
/ hex drivers during removal / re-insertion 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 238 of 356 (D99875607-91)
Page 239: Remove
Figure 5-100 - Tipper with 4:1 Gear Ratio (Left), Tipper with 1:1 Gear Ratio (Right) 13) Remove the cover by following the steps in section 5.3 How to Remove / Re-install the Cover. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 239 of 356 (D99875607-91)
Page 240 Figure 5-101 - Exit Transport and Cables (TOP VIEW FROM FRONT) 18) If you are replacing the exit transport in an ExpressCard 3000, disconnect the foil sensor (Figure 5-102): ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 240 of 356 (D99875607-91)
Page 241 Pull the exit transport slightly forward (or out) and cut the cable tie that holds the MSR cable to the main cable on the bottom back of the exit transport’s base. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 241 of 356 (D99875607-91)
Page 242 21) Carefully lift the exit transport module and tipper module out of the device as a single unit and set them aside. Hold the modules together so the cables between them do not tear loose. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 242 of 356 (D99875607-91)
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: Re-Install
Figure 5-104 - Disconnecting Cable for Easier Access Figure 5-105 - Tipper Patch Cable for Controller Firmware Version F06 or Higher ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 244 of 356 (D99875607-91)
Page 245 2) Make sure the embosser wheel is rotated so the empty tines are facing the exit transport and tipper. 3) Place the new exit / tipper modules on the top deck. Do not let them touch the embosser wheel. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 245 of 356 (D99875607-91)
Page 246 6) Re-connect the MSR cable to the exit transport module: a) Connect the MSR cable to the flex cable inside the left side of the exit transport. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 246 of 356 (D99875607-91)
Page 247 15) Set the ExpressCard to use the calibrated temperature of the heater included with the new tipper: a) Look at the tipper heater on the right side of the tipper to find the calibrated temperature. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 247 of 356 (D99875607-91)
Page 248 16) On the touchscreen, navigate to Menu > Samples , create a sample card, and make sure the device functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 248 of 356 (D99875607-91)
Page 249: How To Remove / Re-Install The Tipper Module
Approximate time to remove: 15 minutes plus any sub-procedures Approximate time to re-install: 30 minutes plus any sub-procedures Figure 5-107 - Tipper Module (FRONT LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 249 of 356 (D99875607-91)
Page 250 It is located in the front middle of the top deck plate, just to the rear of the card output bin. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 250 of 356 (D99875607-91)
Page 251: Tools, Materials, And Documents
/ hex drivers during removal / re-insertion 1 ea. Pen or pencil 1 ea. Paper and clipboard 1 ea. Digital camera or smartphone with camera ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 251 of 356 (D99875607-91)
Page 252: Remove
Figure 5-108 - Tipper with 4:1 Gear Ratio (Left), Tipper with 1:1 Gear Ratio (Right) 5) Remove the cover by following the steps in section 5.3 How to Remove / Re-install the Cover. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 252 of 356 (D99875607-91)
Page 253 LEFT). If the cable is clipped to the heater, the heater cable and sensor cable from the clips (Figure 5-110 RIGHT). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 253 of 356 (D99875607-91)
Page 254 10) If the heater cable and sensor cable are held together with a cable tie, cut the cable tie and discard it. 11) Unplug the tipper heater cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 254 of 356 (D99875607-91)
Page 255 (see Figure 5-113). Pay careful attention to any nearby wires as you pull it forward. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 255 of 356 (D99875607-91)
Page 256 Tipper Cam Home Sensor cable. i) From connector on the board, disconnect the Tipper Card Exit Sensor cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 256 of 356 (D99875607-91)
Page 257 16) Use both hands to remove the tipper module from the device and set it aside, making sure there are no cables caught on it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 257 of 356 (D99875607-91)
Page 258: Re-Install
Figure 5-116 - Tipper Patch Cable for Controller Firmware Version F06 or Higher 2) Make sure the embosser wheel is rotated so the empty tines are facing the exit transport and tipper. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 258 of 356 (D99875607-91)
Page 259 12) Set the ExpressCard to use the calibrated temperature of the heater included with the new tipper: a) Look at the tipper heater on the right side of the tipper to find the calibrated temperature. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 259 of 356 (D99875607-91)
Page 260 13) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 260 of 356 (D99875607-91)
Page 261: How To Upgrade The Tipper Module From 4:1 Model To 1:1 Model
5 - Removal and Re-installation 5.26 How to Upgrade the Tipper Module from 4:1 Model to 1:1 Model Reserved for future use. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 261 of 356 (D99875607-91)
Page 262: How To Remove / Re-Install The Tipper Heater
The heater in the tipper module fuses the tipper foil to the embossed characters on cards. It is a replaceable part that wears out over time and must be replaced approximately every 12,000 cards. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 262 of 356 (D99875607-91)
Page 263: Tools, Materials, And Documents
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Page 264: Remove
Depending on the age of the heater, the cables may be colored differently from the pictures. The procedure is the same. Figure 5-118 - Tipper Heater Cable (TOP VIEW FROM FRONT) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 264 of 356 (D99875607-91)
Page 265 7) If the heater cable and sensor cable are held together with a cable tie, cut the cable tie and discard it. 8) Unplug the tipper heater cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 265 of 356 (D99875607-91)
Page 266 10) Carefully pull the tipper sensor out of the right side of the tipper housing, and move it out of the way by looping it up and over the top of the tipper module. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 266 of 356 (D99875607-91)
Page 267 Figure 5-123 - Supporting the Tipper Heater While Removing / Tightening (TOP VIEW) 12) Slide the tipper heater out the right side of the tipper. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 267 of 356 (D99875607-91)
Page 268 5 - Removal and Re-installation Figure 5-124 - Removing / Re-inserting the Tipper Heater (TOP VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 268 of 356 (D99875607-91)
Page 269: Re-Install
6) Re-insert the tipper sensor into its slot and hold it in place. Route the sensor cable out the front, alongside the heater cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 269 of 356 (D99875607-91)
Page 270 8) Re-connect the tipper heater cable to the plug on the left side of the tipper (see Figure 5-120). 9) Re-install a cable tie to hold the heater and sensor cables together. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 270 of 356 (D99875607-91)
Page 271 17) Set the ExpressCard to use the calibrated temperature of the heater included with the new tipper: a) Look at the tipper heater on the right side of the tipper to find the calibrated temperature. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 271 of 356 (D99875607-91)
Page 272 , create a sample card, and make sure the device functions properly and the sample looks correct. 19) Return the tipper heater and report form to MagTek for recycling. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 272 of 356 (D99875607-91)
Page 273: How To Remove / Re-Install The Embedded Pc
(“tub”) in the device, and is mounted to a tray that slides into two tracks built in to the bottom of the lower deck. Figure 5-126 - Embedded PC (TOP VIEW FROM REAR) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 273 of 356 (D99875607-91)
Page 274: Tools, Materials, And Documents
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Page 275: Remove
(see Figure 5-128). While pulling, use a flashlight and other tools as appropriate to make sure its cables do not snag inside the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 275 of 356 (D99875607-91)
Page 276 The connectors are shown in Figure 5-129. Figure 5-129 - Connectors Near Right Edge of Embedded PC (TOP VIEW FROM RIGHT) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 276 of 356 (D99875607-91)
Page 277 COM1 and COM2, and one ribbon cable connected to the multi-colored front panel connector. If there is silicone adhesive holding any of the connectors, remove it completely. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 277 of 356 (D99875607-91)
Page 278 12) Make sure there are no cables connected to the embedded PC, set it aside on a suitable work surface, and remove any remaining adhesive. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 278 of 356 (D99875607-91)
Page 279: Re-Install
3) Line up the embedded PC tray with its tracks on the bottom of the lower deck (see Figure 5-133). Figure 5-133 - Tracks for Embedded PC and Main Logic Board (RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 279 of 356 (D99875607-91)
Page 280 15) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 280 of 356 (D99875607-91)
Page 281: How To Remove / Re-Install The Embedded Pc Solid State Drive (Ssd)
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Page 282: Remove
Figure 5-135 - Solid State Drive Screws (TOP VIEW FROM RIGHT) 4) Remove the SSD from the embedded PC and set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 282 of 356 (D99875607-91)
Page 283: Re-Install
8) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 283 of 356 (D99875607-91)
Page 284: How To Remove / Re-Install The Main Logic Board (Mlb)
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Page 285: Remove
Restoring the device’s functionality in this case requires reloading the bootloader, which requires an RMA to return the MLB to the manufacturer for rework or replacement. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 285 of 356 (D99875607-91)
Page 286 6) Use the finger holes to slowly and carefully pull the MLB out of the device, and set it aside on an appropriate work surface. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 286 of 356 (D99875607-91)
Page 287: Re-Install
6) On the touchscreen, navigate to > , create a sample card, and make sure the device Menu Samples functions properly and the sample looks correct. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 287 of 356 (D99875607-91)
Page 288: How To Remove / Re-Install The Power Controller And Backplane
– to a long tray that runs along nearly the entire width of the device. Figure 5-141 - Power Controller and Backplane Connector (LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 288 of 356 (D99875607-91)
Page 289: Tools, Materials, And Documents
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Page 290: Remove
(see Figure 5-144). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 290 of 356 (D99875607-91)
Page 291 10) Unplug all five connectors from the left connector panel, noting which cable connects where. 11) Behind the left side access door, locate the power controller board, indicated in Figure 5-146. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 291 of 356 (D99875607-91)
Page 292 14) Disconnect the cables from the three connectors, and move them out of the way toward the outsides of the left side access door. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 292 of 356 (D99875607-91)
Page 293 15) Use the finger holes to continue carefully pulling the tray out of the device. Make sure it does not snag on any cables or other parts. Remove it from the device and set it aside in a static-safe location. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 293 of 356 (D99875607-91)
Page 294: Re-Install
Figure 5-148 - Cable Routing for Inserting Power Controller (LEFT VIEW) Figure 5-149 - Pulling Power Controller Cables to Right Access Door (RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 294 of 356 (D99875607-91)
Page 295 5 - Removal and Re-installation Figure 5-150 - Routing Power Supply Cables Before Final Insertion (LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 295 of 356 (D99875607-91)
Page 296: How To Remove / Re-Install The Ac Filter (Power Supply Jack)
It is located on the rear center of the device. Figure 5-151 - AC Filter (REAR VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 296 of 356 (D99875607-91)
Page 297: Tools, Materials, And Documents
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Page 298: Remove
5) Using the flashlight, look through the left side access door and locate the AC filter where it enters the case (see Figure 5-154). You can identify it by the three electrical connectors attached to it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 298 of 356 (D99875607-91)
Page 299 7) Disconnect the cable from the AC filter. If the connectors are tight, loosen them by wiggling them from side to side while pulling on the connector. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 299 of 356 (D99875607-91)
Page 300 5 - Removal and Re-installation Figure 5-156 - AC Filter Connectors 8) Set the AC filter aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 300 of 356 (D99875607-91)
Page 301: Re-Install
7) If MagTek has not requested parts for analysis, dispose of the AC filter. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 301 of 356 (D99875607-91)
Page 302: How To Remove / Re-Install The Power Supply
Figure 5-158 - Power Supply (FRONT LEFT VIEW FROM ABOVE) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 302 of 356 (D99875607-91)
Page 303: Tools, Materials, And Documents
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Page 304: Remove
One person MUST hold the device at all times to keep it stable on the work surface. Figure 5-159 – One Person Keeps the Device Stable (LEFT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 304 of 356 (D99875607-91)
Page 305 5) Locate the power supply on the rear left side of the device, behind the left side access door. Figure 5-161 - Power Supply (LEFT SIDE VIEW) 6) Remove the clear plastic cover that protects the power supply inputs. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 305 of 356 (D99875607-91)
Page 306 9) Use the No. 2 Phillips screwdriver to loosen the screws holding the power supply output cables, then disconnect the cables. See Figure 5-164. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 306 of 356 (D99875607-91)
Page 307 12) If you are not immediately installing a replacement, with a partner, safely and carefully move the device back to a stable operating position. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 307 of 356 (D99875607-91)
Page 308: Re-Install
If the device does not power on or function properly, contact MagTek Support Services (see Appendix A Technical Support). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 308 of 356 (D99875607-91)
Page 309: How To Remove / Re-Install The Ethernet Jack
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Page 310: Remove
6) Use the wire cutters or diagonal side cutters to cut the plug off the Ethernet cable as shown in Figure 5-167. Disconnect the plug from the embedded PC and set it aside. Figure 5-167 - Cut Ethernet Cable (RIGHT VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 310 of 356 (D99875607-91)
Page 311 Use just your index finger to press on the clip, and pull the whole Ethernet jack toward you. The clip you are pulling on will disengage from the case with a click. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 311 of 356 (D99875607-91)
Page 312 12) Carefully thread the cable out of the device through the left side access door, making sure not to let it get hung up on anything inside the device. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 312 of 356 (D99875607-91)
Page 313: Re-Install
Device Authorize/Deauthorize authorize/deauthorize connection is successfully tested.” 11) If MagTek has not requested parts for analysis, dispose of the Ethernet jack, Ethernet plug, and cable. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 313 of 356 (D99875607-91)
Page 314: How To Remove / Re-Install The Magnetic Stripe Reader (Msr) Module
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Page 315: Remove
8) Pull the MSR out of the cover and disconnect its cable. 9) Set the MSR aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 315 of 356 (D99875607-91)
Page 316: Re-Install
PC). You should not have to replace the cable during standard MSR replacement. Figure 5-175 - Magnetic Stripe Reader Connector to Embedded PC (TOP VIEW FROM REAR) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 316 of 356 (D99875607-91)
Page 317: How To Remove / Re-Install The Touchscreen
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Page 318 Figure 5-177 - Touchscreen Retaining Plate Screws (REAR VIEW) 6) Remove the touchscreen retaining plate and set it aside. 7) Remove the touchscreen and set it aside. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 318 of 356 (D99875607-91)
Page 319 12) Use the touchscreen to navigate through several menus to make sure it functions properly. 13) Perform any relevant adjustments from section 6 Adjustments, notably section 6.1 How to Calibrate the Touchscreen. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 319 of 356 (D99875607-91)
Page 320 If finger presses on the 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 administrator and accessing the Windows desktop.
Page 321 8) Repeat for all Xes that appear on the screen until the system reports “4 points calibration completed. Press[Ok] to continue.” 9) Press the button to dismiss the popup window. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 321 of 356 (D99875607-91)
Page 322 6 - Adjustments 10) Press the button at the bottom of the eGalaxTouch: USB Controller Touchkit : USB window to close it. Controller ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 322 of 356 (D99875607-91)
Page 323 11) Press the button. Printer Eject 12) Remove the card from the image printer exit and recycle it. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 323 of 356 (D99875607-91)
Page 324 13) Re-install hopper 2 and hopper 3 in the device. 14) Press the button to return to the page. Status Status ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 324 of 356 (D99875607-91)
Page 325 Ribbon YMCKO was successfully detected and press the button. configured 5) Press the button to launch the advanced page. Advanced Printer Utility ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 325 of 356 (D99875607-91)
Page 326 6) Press the Auto Self Adj button. 7) Wait about 10 seconds and listen for the image printer to stop moving. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 326 of 356 (D99875607-91)
Page 327 This sets the distance cards will be pushed out of the printer on exit. The Send box should display Response ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 327 of 356 (D99875607-91)
Page 328 6 - Adjustments g) Press the Close button to return to the Printer Utility page. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 328 of 356 (D99875607-91)
Page 329 This is also the maximum resolution of the ExpressCard card design XML files. Because of this, MagTek does not prescribe any additional printer alignment on the ExpressCard line at this time.
Page 330 6) Increase the X size (length) of the image on the card by following these steps: ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 330 of 356 (D99875607-91)
Page 331 If the test cards show wrinkled edges or other problems, lower the value closer to where it was to start, and re-try test cards until they are created successfully. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 331 of 356 (D99875607-91)
Page 332 16) Make sure the card is pushed far enough toward the front of the device that it pushes on and raises the metal justifier flag next to the printer exit (even just a little bit is OK). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 332 of 356 (D99875607-91)
Page 333 Repeat the steps in this section until the card clamps correctly when it exits the printer. Keep the card in the XY Transport for the next section. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 333 of 356 (D99875607-91)
Page 334 Exit Eject 12) Press the Status button to return to the Status page. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 334 of 356 (D99875607-91)
Page 335 You can read the current depth by looking at the shape carved into the side of the knuckle that faces the card (see Figure 6-4). Figure 6-4 - Embosser Knuckle Heights Key (+3 = Most Pressure, -3 = Least Pressure) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 335 of 356 (D99875607-91)
Page 336 Make sure the inked portions line up with each other as shown in Figure 6-5. Figure 6-5 - Marking Factory Default Knuckle Position (REAR VIEW) ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 336 of 356 (D99875607-91)
Page 337 4 and 10. If the value is not in that Calibrate Wheel Home range, report the unit’s failure to calibrate within the acceptable range. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 337 of 356 (D99875607-91)
Page 338 9) Open the top access door and inspect the embosser tine position to make sure the currently selected tine is centered in the embosser bridge opening. 10) Press the Status button to return to the Status page. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 338 of 356 (D99875607-91)
Page 339 8) Repeat the process for FontID2 and any other fonts shown on the embosser base. 9) Press the button to save the new settings. Save ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 339 of 356 (D99875607-91)
Page 340 Figure 6-8 - Measuring Embossed Character Relief Height ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 340 of 356 (D99875607-91)
Page 341 Figure 6-9 - Font IDs Figure 6-10 - Effects of Unbalanced Top / Bottom Embosser Settings ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 341 of 356 (D99875607-91)
Page 342 Bot Cartridge Unload 4) Press the Indenter Move button. The device will move the indenter to the unload position. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 342 of 356 (D99875607-91)
Page 343 If the letters were too far to the rear of the device, enter a larger number for . You probably only need to change by 1-5 steps. BotCardTridgeHomeToIndent ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 343 of 356 (D99875607-91)
Page 344 10) Repeat the steps in this section until the negative letters or numbers on the rear indent cartridge are centered between the top and bottom edge. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 344 of 356 (D99875607-91)
Page 345 Positions, with the following modifications:  Everywhere the steps specify “Bottom” or “Bot,” read as “Top.”  Everywhere the steps specify “Rear,” read as “Front.” ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 345 of 356 (D99875607-91)
Page 346 Tipper Heater Temp written on the side of the heater. 4) Press the Save button. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 346 of 356 (D99875607-91)
Page 347 Save 6.8.3 Align Card Position In Tipper 1) Make sure there is foil in the tipper foil cartridge ((see D99875600 ExpressCard 2000 Installation 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 secure storage or disposal before using them.
Page 348 If you reached a maximum for the Tipper Motor Angle setting and the device is still not covering embossed characters completely, increase the Tipper Motor Time setting by steps of 1ms until the tipper covers properly. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 348 of 356 (D99875607-91)
Page 349 A typical Foil Cool Time is 40ms. There are no specific calibration steps for adjusting the tipper cooling time. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 349 of 356 (D99875607-91)
Page 350 5) If you determine the root cause of the problem is a specific part or sub-assembly, repair or replace it according to the steps in section 5 Removal and Re-installation. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 350 of 356 (D99875607-91)
Page 351 7.1.6 Error Message “Unable to Start the MTECJobServer” / Error Message “Error Opening Controller” See section 7.1.7 Main Logic Board Diagnostics and Troubleshooting. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 351 of 356 (D99875607-91)
Page 352 Return Code Error 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 firmware has become corrupted and must be reloaded, but the bootloader is still intact.
Page 353 Appendix A - Technical Support 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 United States, contact your local sales representative. Phone: (651) 415-6800...
Page 354 The designation of colored ribbon by the panels of color in the YMCKO order in which they are applied: Yellow (Y), Magenta (M), Cyan (C), Black (K) and Overlay (O). ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 354 of 356 (D99875607-91)
Page 355 Yellow (Y), Magenta (M), YMCKOK Cyan (C), Black (K), Overlay (O), Black (K) (used for backside, black only printing). ZCMK Zone Control Master Key ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 355 of 356 (D99875607-91)
Page 356 Appendix C Key Loading For information about loading keys for chip cards, see D99875603 EC2000 How to Inject Keys for Contactless Cards. ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual Page 356 of 356 (D99875607-91)

This manual is also suitable for:

Expresscard 3000

Magtek ExpressCard 2000 Hardware Service Manual

1 Required Tools, Materials, and Documents

2 Introduction

3 Preventive Maintenance Procedure (EC2000)

4 Preventive Maintenance Procedure (EC3000)

5 Removal and Re-Installation

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Summary of Contents for Magtek ExpressCard 2000