Magtek ExpressCard 2000 User manual

MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: [phone] I Technical Support: [phone]
www.magtek.com
ExpressCard 2000
Instant Issuance Card Personalization System
XY Transport Module Replacement Procedure
September 22, 2014
Manual Part Number:
99875703-1.01
REGISTERED TO ISO 9001:2008

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Copyright © 2006 - 2014 MagTek, Inc.
Printed in the United States of America
Information in this publication is subject to change without notice and may contain technical inaccuracies
or graphical discrepancies. Changes or improvements made to this product will be updated in the next
publication release. No part of this document may be reproduced or transmitted in any form or by any
means, electronic or mechanical, for any purpose, without the express written permission of MagTek, Inc.
MagTek® is a registered trademark of MagTek, Inc.
MagnePrint® is a registered trademark of MagTek, Inc.
Magensa™ is a trademark of MagTek, Inc.
MagneSafe™ is a trademark of MagTek, Inc.
ExpressCard 2000is a trademark of MagTek, Inc.
Microsoft® and Windows® are registered trademarks of Microsoft Corporation.
All other system names and product names are the property of their respective owners.
Table 0.1 - Revisions
Rev Number
Date
Notes
1.01
09/22/2014
Initial release derived from 99875607-5.01-DRAFT

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SAFETY
This product has been evaluated by multiple safety certification agencies, including
Underwriters Laboratories (UL) and the United States Federal Communications
Commission (FCC Class A and Class B), and is designed to protect both the user and the
device. This document is written specifically to work in conjunction with these safety and
integrity features to protect the user and the device. It is very important to follow all steps
in the product documentation carefully, in the order in which they are described, and at
the recommended times. Failure to do so could result in personal injury, and / or cause
damage to the device, and / or void the product warranty.
The information within this manual has been prepared for use by trained professional
service personnel and is not intended for general use. To maintain the safety and integrity
of the machine, follow the procedures described in this manual carefully.
For your personal safety and to prevent damage to the device, disconnect power from the
device before you connect or disconnect any cable, electronic board, or assembly.
SAFETY REQUIREMENTS
Caution: Never do any of the following:
DO NOT use a ground adapter plug to connect equipment to a power socket-outlet that lacks a ground
connection terminal.
DO NOT attempt any maintenance function that is not specifically described in this manual or in
other ExpressCard 2000 instructional documents published by MagTek.
DO NOT override or “cheat” electrical or mechanical interlock devices.
DO NOT use EC2000 supplies or cleaning materials for other than their intended purposes.
DO NOT operate the equipment if you or anyone else have noticed unusual noises or odors.
Consider the following before operating the ExpressCard 2000:
Connect the EC2000 to a properly grounded AC power socket-outlet. If in doubt, have the socket-
outlet checked by a qualified electrician. Improper connection of the device’s grounding conductor
creates a risk of electric shock.
Place the EC2000 on a solid surface that can safely support the device’s weight support the weight of
the EC2000 PLUS the weight of a person leaning against the device (such as a service technician).
Be careful when moving or relocating the device. Use proper lifting techniques.
Use materials and supplies specifically designed for MagTek devices. Using unsuitable materials
may result in poor performance, and in some cases may be hazardous.

1 - Table of Contents
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Table of Contents
Table of Contents ............................................................................................................................... 4
1Required Tools, Materials, and Documents ........................................................................... 5
1.1 Required Tools..................................................................................................................... 5
1.2 Suggested Tools .................................................................................................................. 5
1.3 Required Materials ............................................................................................................. 5
1.4 Suggested Materials........................................................................................................... 5
1.5 Required Software and Documents................................................................................. 5
2Introduction ................................................................................................................................. 6
3XY Transport Module Replacement Procedure...................................................................... 7
3.1 Prepare the Device ............................................................................................................. 7
3.2 Remove / Re-install the XY Transport Module............................................................... 8
3.3 How to Calibrate the XY Transport Module...................................................................12

1 - Required Tools, Materials, and Documents
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1Required Tools, Materials, and Documents
1.1 Required Tools
Part Number
Quantity
Description
33011008
1 ea.
ASM TOOL KIT,FIELD SERVICE,EC2000
1.2 Suggested Tools
Part Number
Quantity
Description
N/A
1 ea.
Flashlight
N/A
1 ea.
Hemostat pliers or equivalent
1.3 Required Materials
Part Number
Quantity
Description
33070932
1 ea.
ASM REPLACEMENT KIT,XY TRANSPORT
MODULE,EC2000
1.4 Suggested Materials
Part Number
Quantity
Description
33011009
1 ea.
ASM KIT,STARTER,SPARE,FIELD SERVICE,EC2000
1.5 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
99875600
1 ea.
MNL USER INSTALL & OPERATION MANUAL,EC2000
99875607
1 ea.
MNL HARDWARE SERVICE MANUAL,EC2000

2 - Introduction
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2Introduction
This procedure describes how to replace the XY transport module in the ExpressCard 2000 (EC2000),
and is based on content in 99875607 ExpressCard 2000 Hardware Service Manual. It assumes the
reader is familiar with basic operation of the ExpressCard 2000’s user and maintenance functions, so
many of the cross-references to deeper “how-to”procedures from that manual have been removed for
brevity.
The information in this document is intended for use by trained professional service
personnel only. It is not intended for general use. To maintain the safety and integrity of
the device, it is important to follow the procedures laid out in this document as-written and
in the order provided.
CAUTION: For your personal safety, and to prevent damage to the device, disconnect
power from the ExpressCard 2000 before you connect or disconnect any cable, electronic
board, or assembly.

3 - XY Transport Module Replacement Procedure
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3XY Transport Module Replacement Procedure
3.1 Prepare the Device
Prepare the device for service by following these steps:
1) Offer the customer the opportunity to remove any proprietary or security-sensitive consumables from
the device, including card stock, image printer ribbons, indent cartridges, and tipper foils. Some
consumables contain negative imprints of cardholder data and must be handled securely.
2) Make sure the device is powered on and connected to the network.
3) Open the top access door.
4) Inspect the device for any items that do not belong inside the cover, and remove them (examples
include loose mechanical parts, cards, insect or animal leavings, or jewelry).
5) Power down the device.
6) Disconnect the device’s power and network cables and any security hardware.

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3.2 Remove / Re-install the XY Transport Module
Approximate time to remove: 15 minutes plus any sub-procedures
Approximate time to re-install: 15 minutes plus any sub-procedures
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.
Figure 3-1 - Removing and Re-Installing the XY Transport Module (FRONT RIGHT VIEW)
Follow these steps to remove the XY transport module from the device:
1) Disengage and lean back the top access door by following the steps for removing the top access door
in 99875607 ExpressCard 2000 Hardware Service Manual. Stop at the point where the top
access door is leaning up and back behind the device.
2) Move the XY transport toward the front of the device (see 99875607 ExpressCard 2000 Hardware
Service Manual for details).
3) Locate the XY transport’s ground cable, which is connected to the deck plate behind the image printer
as shown in Figure 3-2.

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Figure 3-2 - XY Transport Ground Cable (TOP VIEW FROM REAR)
4) Use the No. 2 Philips screwdriver to remove the screw, and set it aside.
5) Snap open the XY transport ribbon cable clamp between the rails as shown in Figure 3-3.
Figure 3-3 - XY Transport Ribbon Cable (TOP VIEW FROM FRONT)
6) Grasping the XY transport ribbon cable by the connector, not the cable itself, disconnect it from the
top deck.
7) Locate the connectors in the middle of the Y stepper connection cable, which runs along the left rail
of the XY transport (see Figure 3-4).
8) Hold the two connectors (not the wires), and disconnect them.

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Figure 3-4 - XY Transport Y Stepper Connection Cable (TOP VIEW FROM LEFT)
9) Use the 1/8” Allen wrench to remove the three screws securing the XY transport to the top deck plate
near the rear of the device (see Figure 3-1) and set them aside.
10) Move the XY transport toward the rear of the device (see 99875607 ExpressCard 2000 Hardware
Service Manual for details).
11) Use the 1/8” Allen wrench to remove the three screws securing the XY transport to the top deck plate
near the front of the device (see Figure 3-1) and set them aside.
12) 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.

3 - XY Transport Module Replacement Procedure
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To re-install the XY transport module, follow these steps:
1) Place the XY transport onto the top deck with the ground cable pointing toward the rear of the device,
lining up the holes in the XY transport module with the corresponding holes in the top deck plate.
2) Inspect around and underneath the XY transport to make sure it isn’t pressing any cables against the
top deck plate or other modules.
3) Make sure the four keys at the corners of the XY transport are seated in the corresponding slots in the
top deck plate (see Figure 3-5). Push the base of the XY transport forward and backward, left and
right, to make sure they prevent it from moving around.
Figure 3-5 - XY Transport Base Keys and Top Deck Plate Holes (TOP RIGHT VIEW)
4) Move the XY transport carriage toward the rear of the device (see ExpressCard 2000 Hardware
Service Manual for details).
5) Use the 1/8” Allen wrench to fasten and tighten the three screws securing the XY transport to the top
deck plate near the front of the device (see Figure 3-1).
6) Move the XY transport carriage toward the front of the device (see ExpressCard 2000 Hardware
Service Manual for details).
7) Use the 1/8” Allen wrench to fasten and tighten the three screws securing the XY transport to the top
deck plate near the rear of the device (see Figure 3-1).
8) Re-connect the Y stepper connection cable (see Figure 3-4).
9) Re-connect the XY transport ribbon cable, with the cable coming off toward the front of the device as
shown in Figure 3-3.
10) Hold the ribbon cable in place in the middle of the clamp. Being careful not to pinch the cable, close
the clamp and press until you feel it lock closed.
11) Use the No. 2 Philips screwdriver (and optionally the hemostat pliers) to re-attach the XY transport
ground cable to the top deck plate behind the image printer.
12) Re-attach the top access door by reversing the steps you used to lean it back.
13) Calibrate the XY transport using the information in section 3.3.
14) From the touchscreen, navigate to Menu > Samples, create a sample card, and make sure the device
functions properly and the sample looks correct.

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3.3 How to Calibrate the XY Transport Module
3.3.1 About Calibrating the XY Transport
There are two parameters that must be calibrated to make sure cards are properly handed off from the
image printer to the XY transport. Each setting represents the number of steps the XY motors should take
to get to the specified location.
One setting tells the image printer how far to push cards out from its exit (the X direction).
One setting tells the XY transport how far toward the front or rear of the device (the Y direction) it
should park to take cards from the image printer. The XY transport should be far enough forward that
cards coming out of the image printer slide into its card clamp and push the spring-loaded rail (the
“justifier”) at the printer exit a short distance (0.04” to 0.06”) toward the front of the device. This
pressure allows the justifier to straighten the card against the XY transport’s card clamp.
If the XY transport needs to be calibrated, follow the steps in this section.
3.3.2 How to Calibrate Printer to XY Transport Handoff
To calibrate where the XY transport goes to take a card from the printer, follow these steps:
1) Navigate to Menu > Settings > Service > MCP Commands to open the Controller Commands
page.
2) Press the Pusher Home button.
3) Press the Shuttle Home button.
4) Next to the “To Hopper” button, select 1from the list and press the To Hopper button.
5) Press the Push To Roller button.
6) Press the Shuttle To Printer button.
7) Press the XY Home button.
8) Press the XY To Printer button.
9) Press the XY To Printer In button.
10) Press the Unclamp Card button.
11) Press the Roll To Printer button.
12) Press the Printer Eject button.
13) Press the Clamp Card button.
14) Make sure the card reaches far enough out of the printer that sticks out just past the second metal
block on the card clamp assembly (both metal blocks are circled in Figure 3-6).
15) Make sure the card touches the back of the black plastic part of the card clamp all along the line
shown in Figure 3-6.
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).

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Figure 3-6 - Card Clamps On Card (FRONT VIEW)
17) If the card doesn’t fit all these conditions, adjust the handoff location by following these steps:
a) Navigate to Menu > Settings > Edit Config to open the first Configuration Editing
password page.
b) Enter password 1234567 and press the Ebutton to open the second password page.
c) Enter password 7654321 to open the Configuration Editing page.
d) Scroll down in the list of settings until you find the PrinterHandoffAdjustmentX setting.
e) If the card did not push far enough toward the second clamp, decrease the
PrinterHandoffAdjustmentX setting by selecting the number in the list, pressing the Cbutton,
then entering the new number on the on-screen keypad and pressing the Ebutton.
f) If the card did not make contact with the plastic portion of the clamp or did not press on the
justifier and raise it a little bit, decrease the PrinterHandoffAdjustmentY setting by clicking the
number in the list, pressing the Cbutton, then entering the new number on the on-screen keypad
and pressing the Ebutton.
g) Press the Save button to save your changes.
h) 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.
3.3.3 How to Calibrate XY Transport to Exit Transport Handoff
To calibrate where the XY Transport goes to push a card into the exit rollers, follow these steps:
1) Make sure you have moved a card to the XY Transport as described in the previous section.
2) Navigate to Menu > Settings > Service > MCP Commands to open the Controller Commands
page.
3) Press the XY To Embosser button.
4) Press the XY To Exit button.
5) Make sure the XY Transport does not bump against the Exit Transport.
6) Make sure the first green roller on the exit ramp is centered on the card.
7) Make sure the card is pushed into the exit ramp past the point where the first green roller touches it.
8) If the card doesn’t fit all three of these conditions, adjust the handoff location by following these
steps:
a) Navigate to Menu > Settings > Edit Config to open the first Configuration Editing
password page.

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b) Enter password 1234567 and press the Ebutton to open the second password page.
c) Enter password 7654321 to open the Configuration Editing page.
d) Scroll down in the list of settings until you find the ExitHandoffAdjustmentX setting.
e) If the XY Transport bumped into the Exit Transport, decrease the ExitHandoffAdjustmentX
setting by selecting the number in the list, pressing the Cbutton, then entering the new number
on the on-screen keypad and pressing the Ebutton. Adjust about 10 steps at a time.
f) If the card did not push far enough into the exit ramp, increase the ExitHandoffAdjustmentX
setting by selecting the number in the list, pressing the Cbutton, then entering the new number
on the on-screen keypad and pressing the Ebutton. Adjust about 10 steps at a time.
g) If the card is off-center from the green roller and is too close to the front of the EC2000, increase
the ExitHandoffAdjustmentY setting by clicking the number in the list, pressing the Cbutton,
then entering the new number on the on-screen keypad and pressing the Ebutton. Adjust about
10 steps at a time.
h) If the card is off-center from the green roller and is too close to the back of the EC2000, decrease
the ExitHandoffAdjustmentY setting by clicking the number in the list, pressing the Cbutton,
then entering the new number on the on-screen keypad and pressing the Ebutton. Adjust about
10 steps at a time.
i) Press the Save button to save your changes.
j) Repeat these steps from step 1 until the card clamps correctly when it exits the printer.
9) Navigate to Menu > Settings > Service > MCP Commands to open the Controller Commands
page.
10) Press the Unclamp Card button to release the card.
11) Press the Exit Eject button to eject the card into the card output hopper.
12) Press the Status button to return to the Status page.