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 /
ExpressCard 3000
Instant Issuance Card Personalization System
Hardware Service Manual
February 2020
Document Number:
D99875607-91
REGISTERED TO ISO 9001:2015

ExpressCard 2000 / ExpressCard 3000| Instant Issuance Card Personalization System | Hardware Service Manual
Page 2 of 356 (D99875607-91)
Copyright © 2006 - 2020 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.
MagneSafe® is a registered trademark of MagTek, Inc.
Magensa™ is a trademark of MagTek, Inc.
ExpressCard 2000and ExpressCard 3000™ are trademarks of MagTek, Inc.
AAMVA™ is a trademark of AAMVA.
American Express® is a registered trademark of American Express Marketing & Development Corp.
ANSI®, the ANSI logo, and numerous other identifiers containing "ANSI" are registered trademarks,
service marks, and accreditation marks of the American National Standards Institute (ANSI).
EMVCo™ and EMV™ are trademarks of EMVCo and its licensors.
ISO® is a registered trademark of the International Organization for Standardization.
MasterCard® is a registered trademark and PayPass™and Tap & Go™are trademarks of MasterCard
International Incorporated.
Microsoft® and Windows® are registered trademarks of Microsoft Corporation.
UL™and the UL logo are trademarks of UL LLC.
Visa® and Visa payWave® are registered trademarks of Visa International Service Association.
TiltWatch® is a registered trademark of ShockWatch, Inc.
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
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Table 0.1 - Revisions
Rev Number
Date
Notes
1.01
Dec 11, 2013
Initial release derived from 99875357-6.01, 33099078-2.01,
99875617-1.01, MagTek Support Services videos
2.01
Jan 14, 2014
Add removal / replacement for tipper heater, hopper module,
exit transport module, exit ramp and tipper module, MLB,
power controller, embedded PC, power supply, MSR,
touchscreen. Update some figures with improved renderings.
Add orientation to cardinal directions. Incorporate warnings
and re-order to support tipper cooling time. Re-order
Replacement and Adjustments chapters for more logical cross-
references. Improve cover removal/re-install instructions. Add
time estimates for replacements. Make terminology and order
of steps more consistent. Start section for troubleshooting
service-only issues. Add introduction to embosser alignment.
Update cleaning photos. Add sensor diagram. Improve content
about security of consumables. Fix image printer replacement
structure. Add details about top deck plate keys / slots.
3.01
May 5, 2014
Fix minor formatting issues; add step to move hopper shuttle
before removing side access doors; add advisory to not pinch
wires when removing left side access door.
4.01
Jun 27, 2014
Update troubleshooting information about uneven tipping;
general updates to tipper heater replacement.
50
Aug 15, 2014
Make parking hopper shuttle a standard part of preparation for
preventive maintenance and removal/replacement.
60
Feb 13, 2015
General cleanup and clarity enhancements; simplify embosser
replacement; modify power supply replacement to not tip
device; add AC filter remove/re-install; add Ethernet jack
remove/re-install; add right side cover replacement; add hopper
transport flex cable replacement; add section about retrieving
dropped hardware; fix MCP button name in hopper transport
cleaning per Support; fix cable orientation in embedded PC
replacement; general cleanup
61
Apr 10, 2015
Update hex wrench sizes for embosser replacement.
70
May 1, 2015
Update section 5.21 and section 1to provide unboxing and re-
packaging steps for embosser module; update section 6.6 to add
information about calibrating embossed character relief height;
miscellaneous clarifications.
80
Oct 30, 2015
Add section 5.6 to support complete replacement of top access
door right latch per customer request; minor update to embosser
photos in section 5.21 and section 6.6.1.
81
Apr 8, 2016
Add steps to lubricate and test embosser hammer pin and
knuckle during preventive maintenance (section 3.12); fix ToC

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Rev Number
Date
Notes
82
Oct 21, 2016
Add section 5.13 How to Remove / Re-install the Image
Printer Top Door Cover based on content from new
D998200131
83
Mar 20, 2017
Update and streamline section 5.8 based on design changes;
misc. clarifications and corrections
84
Nov 6, 2017
Update section 3.5 to specify updating firmware if MagTek
Support Services has supplied a .CAB file; Update section 3.15
to specify direct handoff of consumables; Retrofit standardized
Caution, Warning, Notice tables throughout
90
Jan 17, 2020
Throughout, add separate EC3000 procedures where they differ
substantially from EC2000, including 4 Preventive
Maintenance Procedure (EC3000), section 5.17 How to
Remove / Re-Install the Image Print Head (EC2000 with
ECP2, EC3000), section 5.14 How to Remove / Re-install the
Image Printer Module (EC2000 with ECP2, EC3000); Add
section 5.12 How to Remove / Re-install the Image Print
Head migrated from Installation and Operation Manual;
Remove Aligning Embossed Characters with Printed
Characters (deprecated feature); 6.5.2 fix decrease vs. increase
of values; Migrate tools/materials information to individual
procedures; Add new summary checklist at top of each
procedure; Update tipper heater instructions section 5.27; Add
combined tipper / exit procedure section 5.24 and do
corresponding rewrites to individual modules in sections 5.25
and 5.23 and tipper calibration in section 6.8.1; Add diagnosis
section 7.1.3; Misc. clarifications and corrections.
91
Feb 20, 2020
Re-order section 5replacement procedure subsections to be
consistent with order of card movement through device; Section
5.20 add standard tools and materials subsection; Section 5.22
add standard remove / re-install subsection; Section 5.30 add
standard remove subsection; Sections 5.30 and 7.1, incorporate
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
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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 device, 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
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 remove any of the covers or guards that are fastened with screws. There are no user-
serviceable areas within these covers.
DO NOT override or “cheat” electrical or mechanical interlock devices.
DO NOT use ExpressCard 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 ExpressCard 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 ExpressCard on a solid surface that can safely support the device’s weight plus the weight
of a person leaning against it (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.

0 - Table of Contents
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Table of Contents
Safety.................................................................................................................................................................. 5
Table of Contents .............................................................................................................................................. 6
1Required Tools, Materials, and Documents .......................................................................................13
1.1 Required Tools................................................................................................................................13
1.2 Suggested Tools ............................................................................................................................. 13
1.3 Required Materials.........................................................................................................................14
1.4 Suggested Materials ......................................................................................................................14
1.5 Required Software and Documents ............................................................................................ 15
2Introduction .............................................................................................................................................16
2.1 Recommended Preparation for Service Appointments ...........................................................17
2.2 Important Safety Information ......................................................................................................18
2.3 How to Handle ESD-Sensitive Parts............................................................................................. 19
2.4 Introduction to ExpressCard Components..................................................................................20
2.5 Device Specifications.....................................................................................................................21
2.6 About Installation & Operation .................................................................................................... 21
2.7 How to Open the Top Access Door ..............................................................................................21
2.8 How to Safely Move Transports By Hand....................................................................................22
2.8.1 XY Transport Carriage............................................................................................................22
2.8.2 Hopper Transport Shuttle ..................................................................................................... 23
2.9 How to Use Maintenance Functions On the Touchscreen........................................................ 24
2.9.1 How to Use the MCP Commands Page ..............................................................................25
2.9.2 How to Use the Sensor Utility Page.....................................................................................27
2.9.3 How to Use the Embosser Utility Page................................................................................31
2.9.3.1 About the Embosser Utility Page.................................................................................31
2.9.3.2 How to Move the Embosser Wheel............................................................................. 31
2.9.3.3 How to Move the Embosser Cams (Hammers) .........................................................32
2.9.3.4 How to Change the Embosser Character Depth and Dwell Time........................... 32
2.9.4 How to Use the Character Mapping Page .......................................................................... 34
3Preventive Maintenance Procedure (EC2000)...................................................................................36
3.1 Prepare the Device for Preventive Maintenance.......................................................................38
3.2 Clean the Card Path.......................................................................................................................38
3.3 Clean All Transport Rollers ........................................................................................................... 38
3.4 Update the Software......................................................................................................................41
3.5 Update the Firmware .....................................................................................................................42
3.5.1 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

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3.6 Service the Hopper Module...........................................................................................................46
3.7 Service the XY Transport Module.................................................................................................47
3.8 Service the Exit Transport Module ...............................................................................................50
3.9 Cool the Tipper Heater / Power Down the Device.....................................................................50
3.10 Clean Inside the Device.............................................................................................................51
3.11 Service the Image Printer Module...........................................................................................52
3.12 Service the Embosser Module.................................................................................................. 53
3.12.1 About Servicing the Embosser Module............................................................................... 53
3.12.2 How to Service the Embosser Module ................................................................................ 54
3.13 Service the Electronics ..............................................................................................................58
3.14 Service the Cover........................................................................................................................ 58
3.15 Perform Final Tests....................................................................................................................58
4Preventive Maintenance Procedure (EC3000)...................................................................................59
4.1 Prepare the Device for Preventive Maintenance.......................................................................61
4.2 Deep Clean the Image Printer...................................................................................................... 61
4.3 Clean Transport Rollers................................................................................................................. 61
4.4 Update the Software......................................................................................................................62
4.5 Update the Firmware .....................................................................................................................63
4.5.1 Check Firmware Revision Numbers.................................................................................... 63
4.5.2 Update the Main Logic Board (Controller) Firmware........................................................ 64
4.5.3 Update the Image Printer Firmware ................................................................................... 66
4.6 Service the Hopper Module...........................................................................................................67
4.7 Service the XY Transport Module.................................................................................................67
4.8 Service the Exit Transport Module ...............................................................................................67
4.9 Cool the Tipper Heater / Power Down the Device.....................................................................67
4.10 Clean Inside the Device.............................................................................................................68
4.11 Service the Image Printer Module...........................................................................................68
4.12 Service the Embosser Module.................................................................................................. 69
4.12.1 About Servicing the Embosser Module............................................................................... 69
4.12.2 How to Service the Embosser Module ................................................................................ 70
4.13 Service the Electronics ..............................................................................................................74
4.14 Service the Cover........................................................................................................................ 74
4.15 Perform Final Tests....................................................................................................................74
5Removal and Re-installation.................................................................................................................75
5.1 How to Prepare the Device for Removing / Re-installing Modules........................................ 75
5.2 How to Retrieve Dropped Screws and Other Hardware ........................................................... 76
5.3 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

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5.4 How to Remove / Re-install the Right Side Cover .................................................................... 91
5.4.1 Tools, Materials, and Documents........................................................................................ 91
5.4.2 Remove....................................................................................................................................92
5.4.3 Re-install.................................................................................................................................. 93
5.5 How to Remove / Re-install the Top Access Door .................................................................... 94
5.5.1 Tools, Materials, and Documents........................................................................................ 95
5.5.2 Remove....................................................................................................................................96
5.5.3 Re-install.................................................................................................................................. 98
5.6 How to Remove / Re-install the Top Access Door Right Latch............................................... 99
5.6.1 Tools, Materials, and Documents......................................................................................100
5.6.2 Remove..................................................................................................................................101
5.6.3 Re-install................................................................................................................................104
5.7 How to Remove / Re-install the Side Access Doors ...............................................................106
5.7.1 Tools, Materials, and Documents......................................................................................106
5.7.2 Remove..................................................................................................................................107
5.7.3 Re-install................................................................................................................................108
5.8 How to Remove / Re-install the Hopper Module.....................................................................109
5.8.1 Tools, Materials, and Documents......................................................................................111
5.8.2 Remove..................................................................................................................................112
5.8.3 Re-install................................................................................................................................124
5.9 How to Remove / Re-install the Hopper Module Flex Cable .................................................144
5.9.1 Tools, Materials, and Documents......................................................................................144
5.9.2 Remove..................................................................................................................................145
5.9.3 Re-install................................................................................................................................150
5.10 How to Remove / Re-install the Image Printer Module (EC2000 with ECP1)................155
5.10.1 Tools, Materials, and Documents......................................................................................156
5.10.2 Remove..................................................................................................................................157
5.10.3 Re-install................................................................................................................................160
5.11 How to Remove / Re-install the Image Printer Card Cleaning Roller (EC2000 with ECP1)
162
5.12 How to Remove / Re-install the Image Print Head (EC2000 with ECP1) .......................163
5.13 How to Remove / Re-install the Image Printer Top Door Cover (EC2000 with ECP1)..166
5.13.1 Tools, Materials, and Documents......................................................................................166
5.13.2 Remove..................................................................................................................................167
5.13.3 Re-install................................................................................................................................170
5.14 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

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5.14.3 Re-install................................................................................................................................181
5.15 How to Upgrade the Image Printer Module from ECP1 to ECP2......................................188
5.16 How to Remove / Re-install the Image Printer Card Cleaning Roller (EC2000 with ECP2,
EC3000) 189
5.17 How to Remove / Re-Install the Image Print Head (EC2000 with ECP2, EC3000).......190
5.17.1 Tools, Materials, and Documents......................................................................................191
5.17.2 Remove..................................................................................................................................192
5.17.3 Re-install................................................................................................................................195
5.18 How to Remove / Re-install the Image Printer Top Door Cover (EC3000) .....................197
5.19 How to Remove / Re-install the XY Transport Module.......................................................198
5.19.1 Tools, Materials, and Documents......................................................................................200
5.19.2 Remove..................................................................................................................................201
5.19.3 Re-install................................................................................................................................205
5.20 How to Remove / Re-install the XY Transport Ribbon Cable ............................................207
5.20.1 Tools, Materials, and Documents......................................................................................208
5.20.2 Remove..................................................................................................................................209
5.20.3 Re-install................................................................................................................................211
5.21 How to Remove / Re-install the Embosser Module............................................................214
5.21.1 Tools, Materials, and Documents......................................................................................215
5.21.2 Unpack...................................................................................................................................216
5.21.3 Remove..................................................................................................................................218
5.21.4 Re-install................................................................................................................................221
5.21.5 Pack .......................................................................................................................................224
5.22 How to Remove / Re-install Embosser Fonts......................................................................226
5.22.1 Tools, Materials, and Documents......................................................................................226
5.22.2 Remove and Re-install........................................................................................................227
5.23 How to Remove / Re-install the Exit Transport Module.....................................................228
5.23.1 Tools, Materials, and Documents......................................................................................230
5.23.2 Remove..................................................................................................................................231
5.23.3 Re-install................................................................................................................................234
5.24 How to Remove / Re-install the Combined Tipper Module / Exit Transport Module ....236
5.24.1 Tools, Materials, and Documents......................................................................................238
5.24.2 Remove..................................................................................................................................239
5.24.3 Re-install................................................................................................................................244
5.25 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

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5.26 How to Upgrade the Tipper Module from 4:1 Model to 1:1 Model...................................261
5.27 How to Remove / Re-install the Tipper Heater....................................................................262
5.27.1 Tools, Materials, and Documents......................................................................................263
5.27.2 Remove..................................................................................................................................264
5.27.3 Re-install................................................................................................................................269
5.28 How to Remove / Re-install the Embedded PC...................................................................273
5.28.1 Tools, Materials, and Documents......................................................................................274
5.28.2 Remove..................................................................................................................................275
5.28.3 Re-install................................................................................................................................279
5.29 How to Remove / Re-install the Embedded PC Solid State Drive (SSD).........................281
5.29.1 Tools, Materials, and Documents......................................................................................281
5.29.2 Remove..................................................................................................................................282
5.29.3 Re-install................................................................................................................................283
5.30 How to Remove / Re-install the Main Logic Board (MLB) .................................................284
5.30.1 Tools, Materials, and Documents......................................................................................284
5.30.2 Remove..................................................................................................................................285
5.30.3 Re-install................................................................................................................................287
5.31 How to Remove / Re-install the Power Controller and Backplane ..................................288
5.31.1 Tools, Materials, and Documents......................................................................................289
5.31.2 Remove..................................................................................................................................290
5.31.3 Re-install................................................................................................................................294
5.32 How to Remove / Re-install the AC Filter (Power Supply Jack)........................................296
5.32.1 Tools, Materials, and Documents......................................................................................297
5.32.2 Remove..................................................................................................................................298
5.32.3 Re-install................................................................................................................................301
5.33 How to Remove / Re-install the Power Supply ...................................................................302
5.33.1 Tools, Materials, and Documents......................................................................................303
5.33.2 Remove..................................................................................................................................304
5.33.3 Re-install................................................................................................................................308
5.34 How to Remove / Re-install the Ethernet Jack ...................................................................309
5.34.1 Tools, Materials, and Documents......................................................................................309
5.34.2 Remove..................................................................................................................................310
5.34.3 Re-install................................................................................................................................313
5.35 How to Remove / Re-install the Magnetic Stripe Reader (MSR) Module .......................314
5.35.1 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