MagTek EC2000 99875607 User Manual
ExpressCard 2000
Instant Issuance Card Personalization System
Hardware Service Manual
June 2014
Manual Part Number:
99875607-4.01
REGISTERED TO ISO 9001:2008
MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: (562) 546-6400 I Technical Support: (888) 624-8350
www.magtek.com
Copyright © 2006 - 2014 MagTek, Inc.
Rev Number
Date
Notes
1.01
12/11/2013
Initial release derived from 99875357-6.01, 33099078-2.01,
99875617-1.01, MagTek Support Services videos
2.01
01/14/2014
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 crossreferences. 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
05/05/2014
Fix minor formatting issues; add step to move hopper
transport before removing side access doors; add advisory to
not pinch wires when removing left side access door.
4.01
06/27/2014
Update troubleshooting information about uneven tipping;
general updates to tipper heater replacement.
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
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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.
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0 - Table of Contents
Table of Contents
Table of Contents ............................................................................................................................... 4
1 Required Tools, Materials, and Documents ........................................................................... 7
1.1 Required Tools ..................................................................................................................... 7
1.2 Suggested Tools .................................................................................................................. 7
1.3 Required Materials ............................................................................................................. 7
1.4 Suggested Materials ........................................................................................................... 8
1.5 Required Software and Documents ................................................................................. 8
2 Introduction ................................................................................................................................. 9
2.1 Recommended Preparation for Service Appointments ................................................ 9
2.2 Important Safety Information ........................................................................................... 9
2.3 How to Handle ESD-Sensitive Parts ................................................................................. 9
2.4 Introduction to EC2000 Components ............................................................................ 10
2.5 Device Specifications ....................................................................................................... 10
2.6 About Installation & Operation ....................................................................................... 11
2.7 How to Open the Top Access Door ................................................................................. 11
2.8 How to Safely Move Transports By Hand ...................................................................... 11
2.9 How to Use Maintenance Functions On the Touchscreen .......................................... 12
3 Preventive Maintenance .......................................................................................................... 23
3.1 Prepare the Device for Preventive Maintenance ......................................................... 25
3.2 Clean the Card Path .......................................................................................................... 25
3.3 Clean All Transport Rollers .............................................................................................. 25
3.4 Update the Software ......................................................................................................... 28
3.5 Update the Firmware ........................................................................................................ 29
3.6 Service the Hopper Module ............................................................................................. 33
3.7 Service the XY Transport Module ................................................................................... 34
3.8 Service the Exit Transport Module .................................................................................. 36
3.9 Cool the Tipper Heater / Power Down the Device ....................................................... 36
3.10 Clean Inside the Device ................................................................................................ 37
3.11 Service the Image Printer Module .............................................................................. 38
3.12 Service the Embosser Module ..................................................................................... 39
3.13 Service the Electronics ................................................................................................. 42
3.14 Service the Cover ........................................................................................................... 42
3.15 Perform Final Tests ....................................................................................................... 42
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4 Removal and Re-installation .................................................................................................. 43
4.1 How to Prepare the Device for Removing / Re-installing Modules ........................... 43
4.2 How to Remove / Re-install the Top Access Door ....................................................... 44
4.3 How to Remove / Re-install the Side Access Doors .................................................... 48
4.4 How to Remove / Re-install the Cover .......................................................................... 50
4.5 How to Remove / Re-install the Hopper Module ......................................................... 63
4.6 How to Remove / Re-install the Image Print Head ..................................................... 76
4.7 How to Remove / Re-install the Image Printer Module .............................................. 77
4.8 How to Remove / Re-install the XY Transport Ribbon Cable ..................................... 82
4.9 How to Remove / Re-install the XY Transport Module................................................ 88
4.10 How to Remove / Re-install Embosser Fonts ........................................................... 93
4.11 How to Remove / Re-install the Embosser Module ................................................. 94
4.12 How to Remove / Re-install the Tipper Heater.......................................................101
4.13 How to Remove / Re-install the Tipper and Exit Ramp Module ..........................106
4.14 How to Remove / Re-install the Exit Transport Module ........................................111
4.15 How to Remove / Re-install the Embedded PC......................................................113
4.16 How to Remove / Re-install the Embedded PC Solid State Drive (SSD) ............119
4.17 How to Remove / Re-install the Main Logic Board (MLB) ....................................122
4.18 How to Remove / Re-install the Power Controller and Backplane .....................125
4.19 How to Remove / Re-install the Power Supply ......................................................131
4.20 How to Remove / Re-install the Magnetic Stripe Reader (MSR) Module ..........136
4.21 How to Remove / Re-install the Touchscreen ........................................................138
5 Adjustments ............................................................................................................................141
5.1 How to Calibrate the Touchscreen ...............................................................................141
5.2 How to Calibrate the Hopper Transport Module .........................................................143
5.3 How to Calibrate the XY Transport Module .................................................................145
5.4 How to Calibrate the Embosser Module ......................................................................147
5.5 How to Calibrate the Indenter Module .........................................................................164
5.6 How to Calibrate the Image Printer Module ...............................................................167
5.7 How to Minimize Image Printer Margins .....................................................................172
5.8 How to Calibrate the Tipper Module ............................................................................175
6 Diagnosis .................................................................................................................................178
6.1 Known Symptoms and Possible Causes .....................................................................178
Appendix A Technical Support ................................................................................................179
Appendix B Glossary .................................................................................................................179
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1 - Table of Contents
Appendix C Key Loading ..........................................................................................................180
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1 - Required Tools, Materials, and Documents
Part Number
Quantity
Description
33011008
1 ea.
ASM TOOL KIT,FIELD SERVICE,EC2000
67800019 or equiv.
1 ea.
Small USB keyboard with touchpad mouse
N/A
1 ea.
Small diagonal side cutters
N/A
1 ea.
X-Acto knife (if removing embosser characters)
N/A
1 ea.
Micrometer or digital calipers (if calibrating embosser)
N/A
1 ea.
ESD grounding wrist strap
N/A
1 ea.
ESD mat and/or ESD bags
N/A
1 ea.
USB thumb drive with required software and documentation
N/A
1 ea.
Thin-tipped permanent marker
Part Number
Quantity
Description
N/A
1 ea.
Laptop with available Ethernet port
22350302 or equiv.
1 ea.
10 ft. Ethernet cable (COM ETHERNET CAT5E BLK 10')
N/A
1 ea.
Pen or pencil
N/A
1 ea.
Paper and clipboard
N/A
1 ea.
Flashlight
N/A
1 ea.
Needle nose pliers
N/A
1 ea.
Hemostat pliers
N/A
1 ea.
Slotted screwdriver
N/A
1 ea.
Cable tie tool with adjustable tension
N/A
1 ea.
Multimeter
N/A
1 ea.
Flex Phillips screwdriver OR
Electric screwdriver with flex extension
Part Number
Quantity
Description
97200153
1 ea.
ASM KIT,PREVENTIVE MAINTENANCE,EC2000
N/A
1 ea.
Any replacement kits specified in the work order. For a list of kits,
see 33011011 REF LIST,REPLACEMENT KITS,EC2000
N/A
3 ea.
Cloth, clean and lint-free
1 Required Tools, Materials, and Documents
1.1 Required Tools
1.2 Suggested Tools
1.3 Required Materials
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1 - Required Tools, Materials, and Documents
Part Number
Quantity
Description
97200121 or equiv.
~10ml
MSP ADHESIVE,RTV SILICONE,90ML,CLEAR
If removing image printer, touchscreen, embedded PC, or MSR
Part Number
Quantity
Description
33011009
1 ea.
ASM KIT,STARTER,SPARE,FIELD SERVICE,EC2000
93400047
1 ea.
PRI RIBBON, COLOR YMCKOK EV (R3314)
33070896
1 ea.
ASM RIBBON ASSY,TIP FOIL,SILVER
33070621
1 ea.
AAY ASSY,INDENT CARTRIDGE
Part Number
Quantity
Description
99875600
1 ea.
MNL USER INSTALL & OPERATION MANUAL,EC2000
99875607
1 ea.
MNL HARDWARE SERVICE MANUAL,EC2000
99875609
1 ea.
MNL PARTS CATALOG,EC2000
99875651
1 ea.
REF PROCEDURE,PREVENTIVE MAINTENANCE,EC2000
99875646
1 ea.
REF CHECKLIST,PREVENTIVE MAINTENANCE,EC2000
N/A
1 ea.
EC2000 reference image (C:\ from a working EC2000), loaded onto
USB thumb drive or service laptop
N/A
1 ea.
Set of passwords for the device being serviced
N/A
1 ea.
Factory defaults for the device being serviced
VARIOUS
0 or more
EC2000 software patch .CAB files provided by MagTek Support
Services, loaded onto USB thumb drive or service laptop
1.4 Suggested Materials
1.5 Required Software and Documents
MagTek recommends loading the following required software and documents on the USB thumb drive or
service laptop before visiting the customer site.
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2 - Introduction
2 Introduction
This document provides detailed information about maintaining the ExpressCard 2000 (EC2000). It is
part of the ExpressCard 2000 Service Library, which includes:
99875600 ExpressCard 2000 User Installation and Operation Manual
99875607 ExpressCard 2000 Hardware Service Manual
99875609 ExpressCard 2000 Parts Catalog
Documents in the service library reference each other frequently and are designed to be used together.
2.1 Recommended Preparation for Service Appointments
Before visiting a customer for a service appointment, MagTek recommends you do the following:
1) Review the documentation. For example:
a) 99875600 ExpressCard 2000 User Installation and Operation Manual contains important
information about the device, including Introduction to EC2000 Features, Introduction to
EC2000 Components, Operation, Maintenance, and Troubleshooting.
b) Section 2 Introduction, especially section 2.2 Important Safety Information and section 2.3
How to Handle ESD-Sensitive Parts.
c) All sections relevant to the service you will be performing. Depending on the service order, it
may include section 3 Preventive Maintenance, section 6 Diagnosis, section 5 Adjustments,
and section 4 Removal and Re-installation.
2) Gather and test/inspect all tools, materials, and documents, using section 1 Required Tools,
Materials, and Documents as a guide. If you are performing replacements, also gather and inspect
available replacement parts.
3) Copy software and documents you will need to a USB thumb drive.
4) Print any supporting documents you want to have available in hardcopy form.
5) Print a copy of 99875646 REF EC2000 PREVENTIVE MAINTENANCE CHECKLIST.
6) Test the field service laptop to make sure its browser and network connection are functional.
2.2 Important Safety Information
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 manual.
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.
2.3 How to Handle ESD-Sensitive Parts
To prevent electrostatic discharge (ESD) damage to electronic parts, follow the instructions below:
Keep ESD-sensitive parts in their original shipping containers until you are ready to install them.
When handling ESD sensitive parts, prevent static discharge by moving around as little as possible.
Static charges are produced by rubbing together clothing, carpets, furniture, etc.
Wear an ESD wrist strap connected to a metal part on the device’s chassis, such as the base plate.
This will discharge static electricity from your body.
Hold ESD-sensitive parts by their edges or their mounting trays. Do not touch their pins or circuitry.
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2 - Introduction
Do not place an ESD-sensitive part on the device or on a metal table; put it in an ESD bag or on an
ESD mat.
Use extra caution when working under climate conditions that increase the potential for ESD, such as
cold weather or low humidity.
2.4 Introduction to EC2000 Components
For an introduction to identifying the components of the EC2000, see 99875600 EC2000 User
Installation and Operation Manual.
This manual uses the words “Front,” “Rear,” “Left,” and “Right” to describe where to find various parts
of the device. These terms assume the reader is standing in front of the device facing the touchscreen,
and are shown in Figure 2-1. During service, it is normal to move around the device to get easier access
to parts. In the same way, many of the photos and drawings in this manual show the device from different
angles that make key “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)
2.5 Device Specifications
For Electrical, Acoustical, Environmental, Communication, Physical, Encoding, and other detailed
specifications of the EC2000, see 99875600 EC2000 User Installation and Operation Manual.
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2 - Introduction
2.6 About Installation & Operation
For detailed instructions about planning, installation, operation, and basic maintenance, see 99875600
EC2000 User Installation and Operation Manual.
2.7 How to Open the Top Access Door
For instructions to open the top access door, see 99875600 EC2000 User Installation and Operation
Manual.
Some procedures require removing the top access door completely. For removal instructions, see section
4.2 How to Remove / Re-install the Top Access Door.
2.8 How to Safely Move Transports By Hand
Although the MCP Commands page is the safest way to move parts within the EC2000 (see section
2.9.1 How to Use the MCP Commands Page), occasionally it is necessary to move parts by hand. To
prevent injury or damage to the device, follow these guidelines:
If you need to move the hopper transport or XY transport by hand, pull only on their serrated drive
belts as shown in Figure 2-2. This reduces the risk of damaging the transport.
If you need to move the XY transport 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
You can rotate the rollers on all transports by hand to push/pull cards to where they can be removed.
If a card is stuck in the hopper transport but has not yet gone into the image printer, one easy way to
remove the card is to remove one or two hoppers next to the hopper transport, then pull on its
triangular belt to move the card toward the hopper deck.
If a hopper transport has moved a card mostly into the image printer but the card has become stuck,
remove the card forward through the image printer (toward the XY transport). Do not try to reverse
cards from the image printer into the hopper transport.
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2 - Introduction
Press This Button
Verify This Happens
Pusher Home
Hopper transport’s pusher moves into safe position for move
8 To Hopper
Hopper transport moves to (or stays at) manual feed slot, slot light
flashes
7 To Hopper
Hopper transport moves to (or stays at) hopper 1, slot light stops flashing
6 To Hopper
Hopper transport moves to (or stays at) hopper 1
5 To Hopper
Hopper transport moves to (or stays at) hopper 1
To Manual Feed
Hopper transport moves to (or stays at) manual feed slot, slot light
flashes
4 To Hopper
Hopper transport moves to (or stays at) hopper 1
3 To Hopper
Hopper transport moves to (or stays at) hopper 1
Shuttle Home
Hopper transport moves near hopper 1
2.9 How to Use Maintenance Functions On the Touchscreen
This section explains how to use the maintenance functions on the EC2000’s touchscreen. Most of the
functions let you isolate the various subsystems during troubleshooting to determine the failure point, and
to verify repairs have corrected the problem.
To visually inspect the device while it is running, open the top access door and block the sensor mounted
to the rear left of the top access door track. For convenience, 33011008 ASM TOOL KIT,FIELD
SERVICE,EC2000 provides heat shrink tubing that fits snugly over the top access door sensor. Be sure
to put it back in your toolkit before closing the top access door.
To access most maintenance functions of the device using the touchscreen, do the following:
1) Press the Menu button to open the Main Menu page.
2) Press the Settings button to open the Settings Menu page. The Settings Menu page provides
access to user and service functions of the device, some of which require a password. If customers
have changed the passwords, request the new passwords from them. Otherwise the passwords will be
the factory defaults provided in the sections below.
3) Additional maintenance functions can be accessed from the Settings Menu page by pressing the
Service button to open the Service Menu page. For example, you can use the Sensor Utility page
to view the status of the EC2000’s sensors, or use the MCP Commands page to move the various
parts of the EC2000 individually rather than as part of a standard sequence.
2.9.1 How to Use the MCP Commands Page
The move the various parts of the EC2000 individually rather than as part of a standard sequence, use the
touchscreen to navigate to Menu > Settings > Service > MCP Commands to open the MCP
Commands page. Note that the MCP Commands page may allow you to make moves that could
damage the device -- think carefully before sending a direct move command!
Table 2.1 provides an MCP Commands sequence that tests most subsystems by moving a card from
hopper 1 to the output bin. You can test by pressing each button in the list and verifying the described
action happens correctly. The gray highlighted lines make up a shorter sequence that does the same thing.
Table 2.1 - Controller Buttons and Corresponding Movements
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Press This Button
Verify This Happens
2 To Hopper
Hopper transport moves to (or stays at) hopper 1
1 To Hopper
Hopper transport moves to (or stays at) hopper 1
Bot Cartridge Unload,
Indenter Move
Rear (black) indent cartridge moves out of embosser toward rear of
device
Bot Cartridge Load,
Indenter Move
Rear (black) indent cartridge moves back into embosser
Bot Cartridge Home,
Indenter Move
Rear (black) indent cartridge moves back into (or stays in) embosser
Bot Cart to Indent
Loc., Indenter Move
Rear (black) indent cartridge moves between letters on embosser wheel
Bot Ribbon Advance,
Indenter Move
Ribbon in rear (black) indent cartridge advances by about ¼”
Top Cartridge Unload,
Indenter Move
Only if testing EC2000 with Front Indenter installed:
Front (white) indent cartridge moves out of embosser toward rear of
device
Top Cartridge Load,
Indenter Move
Only if testing EC2000 with Front Indenter installed:
Front (white) indent cartridge moves back into embosser
Top Cartridge Home,
Indenter Move
Only if testing EC2000 with Front Indenter installed:
Front (white) indent cartridge moves back into (or stays in) embosser
Top Cart to Indent
Loc., Indenter Move
Only if testing EC2000 with Front Indenter installed:
Front (white) indent cartridge moves between letters on embosser wheel
Top Ribbon Advance,
Indenter Move
Only if testing EC2000 with Front Indenter installed:
Ribbon in front (white) indent cartridge advances by about ¼”
Roller Consume
Hopper transport’s wheels turn for a few seconds
Push To Roller
Hopper transport takes a card from current hopper
Shuttle To Printer
Hopper transport moves to image printer
Roll To Printer
Hopper transport’s wheels turn for a few seconds to feed card into image
printer. Press Printer Eject button to move card through image printer.
XY Home
XY Transport moves to rear left of device
XY Home X
XY Transport’s X carriage moves to the left
XY Home Y
XY Transport’s Y transport moves to the rear of the device
XY To Printer
XY Transport moves to image printer
XY To Printer In
XY Transport’s X carriage moves toward image printer to engage with
card
Unclamp Card
X carriage’s card clamp rotates to unclamped position
Printer Eject
Card at image printer input is ejected to image printer exit
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2 - Introduction
Press This Button
Verify This Happens
Clamp Card
X carriage clamps card at printer exit
Embosser Home
Embosser wheel moves to first character on wheel (look for empty tines
next to the tine that is currently between the hammers)
Embosser hammers open completely (not squeezing embosser tines)
Wheel Home
Embosser wheel moves to first character on wheel (look for empty tines
next to the tine that is currently between the hammers)
XY To Embosser
XY Transport moves card out of printer and to embosser
CardHomeXY
XY Transport moves card so its lower left corner is between embosser
tines
XY To Exit
XY Transport moves card to Exit Transport’s input rollers
Unclamp Card
X carriage’s clamp releases the card
Exit Reject
Exit transport raises its bottom roller, rolls for a short period of time.
Ramp fan turns on. Card goes into Card Rejection Bin.
Exit Eject
Exit Transport rolls card to exit ramp, ramp fan turns on briefly.
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2 - Introduction
Sensor Name
Function
Printer Exit
Blocked when there is NO card in the image printer exit, and is unblocked when
there is a card in the image printer exit.
X_Home
Blocked when the X carriage on the XY transport is parked at its left edge.
Y_Home
Blocked when the XY transport is parked at the rear of the device.
Card Clamp
Blocked when the card clamp on the XY transport is closed.
Card Home XY
Blocked when the XY transport reaches the front of the device (at the embosser),
regardless of its X position.
Top Cam
Blocked during normal operation and briefly unblocks when the cam that drives
the top embosser hammer reaches specific points in its rotation.
Bottom Cam
Blocked during normal operation and briefly unblocks when the cam that drives
the bottom embosser hammer reaches specific points in its rotation.
2.9.2 How to Use the Sensor Utility Page
To check the real-time status of all EC2000 sensors, use the touchscreen to navigate to Menu > Settings
> Sensors to open the Sensor Utility page. In normal operation with the top access door closed, with
all card stock hoppers inserted, and with the device just powered up and ready to process cards, the
Sensor Utility page should match Figure 2-3.
Figure 2-3 - Sensor Utility Page
To test a sensor, block or unblock it and verify its status changes. Table 2.2 provides descriptions of each
sensor and the cases where it is blocked or unblocked, and Figure 2-4 on page 17 shows where all sensors
are located in the device.
Table 2.2 - EC2000 Sensor Functions
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2 - Introduction
Sensor Name
Function
Card Edge
Blocked EITHER when the embosser daisy wheel is turned such that one of the
tines blocks the sensor, OR when a card enters the area between the embosser
wheels.
Wheel Home
Blocked when the small fin on top of the embosser daisy wheel points toward the
front of the device.
Top Case
Blocked when the top access door is closed.
Shuttle
Exception
Blocked when the hopper transport pushes far enough toward the front of the
device that it mechanically rotates to orient with the manual feed slot.
Hopper Exit
Blocked when a card reaches the point where it is fully and safely loaded from a
hopper into the hopper transport.
Eject Xport
Reserved for future use.
Eject Bin
Reserved for future use.
Exit Just Home
Reserved for future use.
RI Home
Blocked when the rear indent cartridge is in the loaded position (toward the front
of the device).
FI Home
Only used on devices that have the optional front indent module installed. Blocked
when the front indent cartridge is in the loaded position (toward the front of the
device).
Hopper Pull
Unblocked when the card puller on the hopper transport moves in to pick up a card.
Shuttle Home
Blocked when the hopper transport is parked at the rear right corner of the device.
Exception Feed
Blocked when a card just enters the manual feed slot.
RI Unload
Blocked when the rear indent cartridge is in the unload position (toward the rear of
the device).
FI Unload
Only used on devices that have the optional front indent module installed. Blocked
when the front indent cartridge is in the unload position (toward the rear of the
device).
MP Card In
Reserved for future use.
Hopper Card In
Reserved for future use.
Hopper1 Empty
- Hopper7
Empty
Unblocked when there is no hopper installed in the specified hopper slot.
Tipper Cam
Blocked when the tipper heating element is in the up/idle position.
Tipper Grip
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.
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2 - Introduction
Figure 2-4 - All EC2000 Sensors Shown In Red (FRONT VIEW)
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2 - Introduction
2.9.3 How to Use the Embosser Utility Page
2.9.3.1 About the Embosser Utility Page
To manually move the embosser daisy wheel or hammer cam motors, or to adjust the depth of individual
embossed characters, use the touchscreen to navigate to Menu > Settings > Service > Embosser,
then enter service passwords 4567890 and 0987654 to open the Embosser Utility page.
Figure 2-5 - Embosser Utility Page
The “Steps/Direction” box specifies how many steps the motor will take when you press any of the Move
buttons in the top row. Adjust the “Steps/Direction” value by typing a new value on the keyboard, or by
pressing the up and down arrows. Change how quickly the arrow buttons change the value by selecting
the 1 per, 10 per, or 100 per radio buttons; the default is 100 steps.
The following sections specify how to use the Embosser Utility page to perform specific operations.
2.9.3.2 How to Move the Embosser Daisy Wheel
The daisy wheel, driven by the Wheel Motor Move button, contains the set of characters the embosser
can press into cards. Each character is mounted to one of 80 tines numbered 1 through 80. The motor
takes 20 steps to advance from one tine to the next. To move the daisy wheel a full 360 degrees, move it
(80 characters) x (20 steps per character) = 1600 steps.
To move the daisy wheel, follow these steps from the Embosser Utility page:
1) Turn on the Move At Fast checkbox. The daisy wheel is designed and tested to operate at fast speed.
2) Set the number of steps you want the daisy wheel to take (see section 2.9.3.1 About the Embosser
Utility Page) and press the Wheel Motor Move button.
3) Repeat the moves as necessary to complete the test.
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4) Re-home the daisy wheel by pressing either the Counter Clockwise Home or Clockwise Home
button. In normal operation, the daisy wheel homes counter-clockwise.
5) Press the All Motors Stop button to make sure the daisy wheel motor is not energized / holding still.
6) Press the Status button to return to the Status page.
2.9.3.3 How to Move the Embosser Cams (Hammers)
The top and bottom embosser cams, which can be driven by the Top Clamp Motor Move button and
Bottom Clamp Motor Move buttons, squeeze the embosser hammers to imprint raised characters on
cards. In a typical emboss cycle, each of the cam motors takes about 600 steps forward to move the cam
from its home position to press into the card, and 600 in reverse to retract back to the home position. One
step is approximately equal to 0.225 degrees of rotation, so the total emboss cycle covers about 135
degrees.
To move the top embosser cam, bottom embosser cam, or both cams, follow these steps from the
Embosser Utility page:
1) Press the All Motors Stop button to make sure no motor is applying force.
2) If there is nothing in the way of the hammers, press the Top & Bottom Home button to make sure
the cams are not closed. The “home” position is the standard starting position for an emboss cycle.
3) Press either the Counter Clockwise Home button or the Clockwise Home button to make sure the
daisy wheel has a character positioned between the embosser hammers. If the daisy wheel is offcenter, the hammers could damage it.
4) You may encounter a situation during testing where you want to close the hammers to their calibrated
close position, but prevent one embosser hammer from moving during testing; for example, to
prevent damage if something is jammed in the device, or if moving a specific cam would be a safety
hazard. In that type of situation, you can prevent one or both of the cams from moving in the next
step by checking the Do Not Move Top and / or Do Not Move Bottom checkbox. Note: This
feature only locks out movement when pressing the Close Clamp button and will not prevent
clamp movement for any other buttons on the page or during normal device operation.
7) Set the number of steps you want the cam(s) to move (see section 2.9.3.1 About the Embosser
Utility Page) and press the Top Clamp Motor Move or Bottom Clamp Move button, OR press the
Close Clamp button, OR press the All Motors Stop button if you find you have moved too far and
need to release the cams immediately.
8) Repeat the moves as necessary to complete the test.
9) Press the Top & Bottom Home button to make sure the cams are not left closed.
10) Press the All Motors Stop button to make sure no motor is applying force.
11) Press the Status button to return to the Status page.
2.9.3.4 How to Change the Embosser Character Depth and Dwell Time
Over time or after embosser service, an individual embossed character’s height may change to the point
that it doesn’t match other characters. The Emboss Settings page provides access to settings for each
tine on the embosser daisy wheel, which affect the pressing force and hold time for that one character.
The Emboss Settings page provides two ways to change these settings: You can import settings for all
tines from a file on the EC2000’s solid state drive or a USB thumb drive using the Read button, or you
can change each tine’s settings individually. The page also provides a Reset button that will reset all
tine settings to factory defaults.
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Figure 2-6 - Emboss Settings Page
To adjust a single character’s pressing force or hold time, do the following:
1) Open the Emboss Settings page: Navigate to Menu > Settings > Service > Embosser and
enter service passwords 4567890 and 0987654 to open the Embosser Utility page, then press the
Settings button below Set Emboss Hold Time & Height.
2) Press the Get button to refresh the settings shown in the Current Settings in Device list box.
3) Select the tine you want to change in the Tine # drop-down menu. The touchscreen will display the
current settings for that tine in the top row of the page.
4) To adjust how long the embosser hammer will press that specific character into the card before lifting
back off to the embosser home position, change the Hold setting. The setting is in increments of 10
milliseconds, so a value of 5 equals a hold time of 50 ms. In most cases, setting Hold to 0 should
produce acceptable results:
a) Select the Hold field.
b) Enter a new value using the keyboard, or use the up and down arrows to adjust the value. You
can set how quickly the arrows will change the value by pressing the N per tap button.
5) To adjust the depth the hammer will press that specific character into cards, change the Char Height
setting. The EC2000 will add this value to the device’s global EmbossAngleTop and
EmbossAngleBottom settings, or IndentAngleTop and IndentAngleBottom settings, as
appropriate (see section 5.4 How to Calibrate the Embosser). To increase the embossed depth of
that specific character, increase the value; to decrease the embossed depth of a given character,
decrease the value. The valid range is from -127 to +127, but typical values are in the -20 to +40
range.
6) Press the Save All button to save the settings for all tines
7) Press the Status button to return to the Status page.
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2.9.4 How to Use the Character Mapping Page
The Character Mapping page provides support for changing the configuration of characters on the
EC2000 embosser’s daisy wheel, and will most commonly be used in conjunction with the steps in
section 4.10 How to Remove / Re-install Embosser Fonts and in section 4.11 How to Remove / Re-
install the Embosser. Functions include adding new fonts, moving an existing character to a different
tine, and removing a character from a tine.
At any time (such as if you make a mistake that you discover later in testing), you can reset the changes
you made to the daisy wheel and return them to factory defaults by navigating to Menu > Settings >
Service > Wheel Map and pressing the Reset button.
To move a character from one daisy wheel tine to another, follow these steps:
1) Look at the numbers stamped on each daisy wheel tine to determine which tine the character was (or
is) originally on, and which tine you will move it to.
2) If the character is still on the old tine, uninstall it. Every character has a piece on the top daisy wheel
and a second piece on the bottom daisy wheel, so make sure to uninstall both, and to note which piece
belongs on the top and which piece belongs on the bottom.
3) Install both halves of the character on the new tine.
4) From the touchscreen, navigate to Menu > Settings > Service > Char Map to open the first
Character Mapping password page.
5) Enter password 4567890, then press the E key to open the second Character Mapping password
page.
6) Enter password 0987654, then press the E key to open the Character Mapping page.
7) Use the From Current dropdown list to select the old tine where the character was installed.
8) Use the To New Tine dropdown list to select the new tine where the character is now installed.
9) Press the Move button.
10) Repeat the above steps for any additional characters you need to move.
11) Test your changes by creating a sample card or an embosser tuning card.
To remove a character from a daisy wheel tine, follow these steps:
1) Look at the numbers stamped on each daisy wheel tine to determine which tine you want to remove
the character from.
2) If the character is still on the old tine, uninstall it. Every character has a piece on the top daisy wheel
and a second piece on the bottom daisy wheel, so make sure to uninstall both.
3) From the touchscreen, navigate to Menu > Settings > Service > Char Map to open the first
Character Mapping password page.
4) Enter password 4567890, then press the E key to open the second Character Mapping password
page.
5) Enter password 0987654, then press the E key to open the Character Mapping page.
6) Use the From Current Tine dropdown list to select the tine where the character was installed.
7) Press the Clear button.
8) Repeat the above steps for any additional characters you need to remove.
9) Test your changes by creating a sample card or an embosser tuning card.
To add a new character to a daisy wheel tine, follow these steps:
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1) Verify the EC2000 software supports the character(s) you are going to install.
2) Look at the numbers stamped on each daisy wheel tine to find the number of the tine where you will
install the new character.
3) Install the character on the tine. Every character has a piece on the top daisy wheel and a second
piece on the bottom daisy wheel, so make sure to install both, and to put each piece on the correct
half: For embossing fonts and rear indent fonts (FontID1, FontID2, and FontID4), the “punch”
(positive) side goes on the bottom; for front indent fonts (FontID3), the “punch” side goes on the top.
Indent fonts have a “blank” flat side that goes opposite the punch side.
4) Install both halves of the character on the new tine.
5) From the touchscreen, navigate to Menu > Settings > Service > Char Map to open the first
Character Mapping password page.
6) Enter password 4567890, then press the E key to open the second Character Mapping password
page.
7) Enter password 0987654, then press the E key to open the Character Mapping page.
8) Use the Add Char. dropdown list to select what character you are installing (for example, if you are
installing a capital ‘A,’ select 65). Verify you have selected the character you expected to select by
looking at the ASCII Char box next to the dropdown list.
9) Use the Font dropdown list to indicate the type of font you have installed (FontID1-4).
10) Use the To dropdown list to select which tine you have installed the characters on.
11) Press the Add button.
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.
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3 Preventive Maintenance
The EC2000 requires regular preventive maintenance to maintain image quality and reliability. Follow
the steps in each section below to perform preventive maintenance.
Before starting, ask the EC2000 user or customer if they have had any specific problems with the device.
If you need to troubleshoot a specific problem, address that before performing preventive maintenance.
See section 6 Diagnosis for assistance troubleshooting reported issues.
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.
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3.1 Prepare the Device for Preventive Maintenance
To prepare the device for service, follow 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 up and connected to the network.
3) Open the top access door (see 99875600 EC2000 User Installation and Operation Manual).
4) Open the two side access doors (see section 4.3 How to Remove / Re-install the Side Access
Doors).
5) 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).
6) Inspect the mechanical parts inside the device and inside the image printer, paying special attention to
belts, cables, and plastic gears to see if there are signs of wear or damage.
3.2 Clean the Card Path
Clean the card path per the steps in the Maintenance section of 99875600 EC2000 User Installation
and Operation Manual.
3.3 Clean All Transport Rollers
Follow these steps to clean the rollers on the hopper transport, XY transport, and exit transport. Use the
white cleaning cards:
1) Remove hoppers 1 and 2.
2) Remove the tipper foil cartridge (see 99875600 ExpressCard 2000 User Installation and
Operation Manual for detailed instructions) and set it aside in a secure location, or offer it to the
customer for temporary storage or secure disposal.
3) On the touchscreen, navigate to Menu > Settings > Service > MCP Cmds to open the
Controller Commands page.
4) Use the white cleaning card and do not let the rollers take it out of your hand as you clean each set
of rollers as follows:
a) Feed the card partly into the hopper transport and press the Roller Consume button. Hold the
card there until the rollers stop moving.
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Figure 3-1 - Cleaning the Hopper Transport Rollers (TOP VIEW FROM FRONT)
b) Feed the card partly into the left side of the exit transport and press the Exit Eject button. Hold
the card there until the rollers stop moving.
Figure 3-2 - Cleaning the Left Side of the Exit Transport (TOP VIEW FROM FRONT)
c) Feed the 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.
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Figure 3-3 - Cleaning the Right Side of the Exit Transport (TOP VIEW FROM FRONT)
d) Feed the card partly under the exit ramp rollers and press the Exit Eject button. Hold the card
there until the rollers stop moving.
Figure 3-4 - Cleaning the Exit Ramp Rollers (TOP VIEW FROM FRONT)
5) Press the Status button to return to the Status page.
6) Re-install the tipper foil spool assembly with the original tipper foil roll, or obtain and install a new
one from the customer.
7) Re-install hoppers 1 and 2.
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3.4 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 the EC2000. If necessary, you may instead
use the customer’s instant issuance workstation, provided it has Microsoft Internet Explorer and a
USB port with security settings that allow you to read from the USB thumb drive.
2) Launch the Internet Explorer web browser and navigate to https://ec-xxxxxxx, where xxxxxxx is the
device’s serial number. The browser should show an ExpressCard 2000 web interface page.
3) Open the Software Upload link on the left side of the page to display a File to Upload page.
4) Press the Browse… button to launch the Choose File to Upload dialog box.
5) Navigate to the folder that contains the .CAB files you want to apply (such as the field service
laptop’s hard drive or the USB thumb drive).
6) Select the .CAB file you want to apply, and press the Open button to return to the File to Upload
page.
7) Press the Send button to upload the .CAB file to the device. The browser will display a status
message telling you when the patch will be applied (for example, “File Copied Successfully. Update
will be performed during next reboot.”). The device’s touchscreen may also go blank.
8) Restart the device by powering it off, then powering it on. Wait until the touchscreen once again
displays the ExpressCard 2000 Status page.
9) In the web browser, open the Upload Status link on the left side of the page. If the browser reports
“SUCCESS,” repeat these steps for any additional patch .CAB files you need to apply, or continue to
the next section.
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3.5 Update the Firmware
Follow the steps in this section to determine whether the EC2000 firmware needs to be updated, and to
update it if necessary.
3.5.1 Check Firmware Revision Numbers
To check whether the EC2000 has the latest main logic board (MLB) and image printer firmware
installed, follow these steps:
1) Install any software updates MagTek Support Services has provided, using the instructions in section
3.4 Update the Software. This is a very important first step, because new revisions of firmware files
are distributed to the EC2000 via software updates.
2) From the EC2000 touchscreen, press the Help button to open the Help page.
3) In the Version Information list, note the Controller Firmware and Printer Firmware entries.
4) Press the Menu button to launch the Main Menu page.
5) Press the Settings button to launch the Settings Menu page.
6) Press the Load F/W button to launch the Firmware Download password page.
7) Use the on-screen keyboard to enter the password 1234567, then press the E key to launch the
second Firmware Download password page.
8) Use the on-screen keyboard to enter the password 7654321, then press the E key to launch the
Firmware Download page.
9) Note the revision numbers listed for each .hex file in the list. If any revision number does not match
the revision numbers you found on the Help page, update the firmware for that component using the
steps in the following sections.
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3.5.2 Update the Main Logic Board (Controller) Firmware
To update the controller (main logic board / MLB) firmware, follow these steps:
1) From the Firmware Download page, select the Controller radio button.
2) In the list of .hex files, select the file that corresponds to the new revision.
3) Press the Download button to download the .hex file to the controller. The system will report
“Loading the firmware. Please wait….”
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