ExpressCard 2000
Instant Issuance Card Personalization System
Tipper Heater Replacement Procedure
June 2014
Manual Part Number:
99875692-1.01
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
06/27/2014
Initial release derived from 99875607-4.01-DRAFT
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
ExpressCard 2000| Instant Issuance Card Personalization System | Tipper Heater Replacement Procedure
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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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1 - Table of Contents
Table of Contents
Table of Contents ............................................................................................................................... 4
1 Required 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
2 Introduction ................................................................................................................................. 6
3 Tipper Heater Replacement Procedure .................................................................................. 7
3.1 Prepare the Device ............................................................................................................. 7
3.2 Cool the Tipper Heater / Power Down the Device ......................................................... 7
3.3 Remove / Re-install the Tipper Heater ............................................................................ 7
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1 - Required Tools, Materials, and Documents
Part Number
Quantity
Description
33011008
1 ea.
ASM TOOL KIT,FIELD SERVICE,EC2000
N/A
1 ea.
Small diagonal side cutters
Part Number
Quantity
Description
N/A
1 ea.
Flashlight
Part Number
Quantity
Description
33070911
1 ea.
ASM TIPPER HEATER REPLACEMENT KIT,EC2000
Part Number
Quantity
Description
33011009
1 ea.
ASM KIT,STARTER,SPARE,FIELD SERVICE,EC2000
33070896
1 ea.
ASM RIBBON ASSY,TIP FOIL,SILVER
Part Number
Quantity
Description
99875600
1 ea.
MNL USER INSTALL & OPERATION MANUAL,EC2000
99875607
1 ea.
MNL HARDWARE SERVICE MANUAL,EC2000
1 Required Tools, Materials, and Documents
1.1 Required Tools
1.2 Suggested Tools
1.3 Required Materials
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 procedure describes how to replace the tipper heater 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.
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3 - Tipper Heater Replacement Procedure
Approximate time to remove: 15 minutes plus any sub-procedures
Approximate time to re-install: 30 minutes plus any sub-procedures
3 Tipper Heater Replacement Procedure
3.1 Prepare the Device
Prepare the device for preventive maintenance 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 up 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).
3.2 Cool the Tipper Heater / Power Down the Device
1) Navigate to Menu > Settings > Tipper to open the Tipper page.
2) Press the Set Heater OFF button to turn off the tipper heater.
3) Note the value under Current Tipper Temp. If the tipper temperature is 50 degrees Centigrade or
hotter, the tipper heater is not safe to touch.
4) Take note of the current time, and plan your work to allow enough time for the tipper heater to cool,
which can take up to 15 minutes. You may be able to use compressed air to cool it more quickly.
5) Power down the device.
3.3 Remove / Re-install the Tipper Heater
Caution: The tipper heater is hot and can burn your skin! Make sure the device has been
turned off, or the heater has been turned off and no cards have been produced, for at least
10 minutes to allow adequate cooling time before touching the tipper heater.
To remove the tipper heater, follow these steps:
1) Prepare the device for replacing parts by following the steps in section 3.1. At the end, the device
should be powered down with all external cables safely disconnected.
2) Allow the tipper heater enough time to cool below 50°C so it is not too hot to couch. Cooling can
take up to 15 minutes, so begin the service appointment with work away from the tipper heater.
3) 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.
4) Locate the tipper heater cable, which comes out the front of the tipper above the exit ramp.
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3 - Tipper Heater Replacement Procedure
Figure 3-1 - Tipper Heater Cable (TOP VIEW FROM FRONT)
5) Cut the plastic cable tie that holds the tipper heater cable connectors to the left side of the tipper
module. If the cable does not have connectors like those shown in Figure 3-2, you may be working
on an older device; contact MagTek for alternate instructions.
Figure 3-2 - Tipper Heater Cable Tie (TOP LEFT VIEW)
6) Unplug the tipper heater cable.
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3 - Tipper Heater Replacement Procedure
Figure 3-3 - Tipper Heater Plug (FRONT RIGHT VIEW)
7) Use the 3/32” Allen wrench to remove the two screws that secure the tipper sensor to the tipper
housing, and set them aside.
Figure 3-4 - Tipper Sensor Screws (FRONT RIGHT VIEW)
8) Carefully pull the tipper sensor out of the right side of the tipper housing, and move it out of the way
by looping it up and over the top of the tipper module.
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3 - Tipper Heater Replacement Procedure
Figure 3-5 - Removing and Re-installing the Tipper Sensor (FRONT RIGHT VIEW)
9) Use the 1/8” L-handle Allen wrench to remove the two spring-loaded posts that hold the tipper heater
in the tipper module, and set them aside.
Figure 3-6 - Supporting the Tipper Heater While Removing / Tightening (RIGHT VIEW)
10) Slide the tipper heater out the right side of the tipper.
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3 - Tipper Heater Replacement Procedure
Figure 3-7 - Removing / Re-inserting the Tipper Heater (TOP VIEW FROM FRONT)
11) Determine the number of cards the tipper heater has produced, and record the number. Set the tipper
heater aside to return to MagTek for recycling.
To re-install the tipper heater, follow these steps:
1) Orient the tipper heater with the flat side down and the cables coming off to the right (Figure 3-7).
2) Run the cable out the front of the tipper as shown in Figure 3-1 and Figure 3-4.
3) Hold the tipper heater up in place with one hand as shown in Figure 3-6.
4) Insert and hand-tighten the right spring-loaded post, making sure it holds the tipper heater up.
Figure 3-8 - Hand-tightening the First Spring-loaded Post (RIGHT VIEW)
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3 - Tipper Heater Replacement Procedure
5) Insert the left spring-loaded post, move the tipper heater around until it lines up, and use the 1/8” L-
handle Allen wrench to tighten it.
6) Tighten the right spring-loaded post.
7) Re-insert the tipper sensor into its slot (see Figure 3-5) and hold it in place.
8) Use the 3/32” Allen wrench to insert and tighten the two screws that hold the tipper sensor (see
Figure 3-4).
9) Re-connect the tipper heater cable to the plug on the left side of the tipper (see Figure 3-3).
10) Re-install a cable tie in the anchor on the left side of the tipper module. Bundle the tipper heater
cable with the other cables and tie them down in the middle of the tipper heater plug (Figure 3-2).
11) Perform any additional service that requires the device to be powered off and open.
12) Re-install the tipper foil spool assembly with the original tipper foil roll, or obtain and install a new
one from the customer.
13) Close the top access door.
14) Re-attach the power cable, network cable, and any security hardware.
15) Power up the device.
16) From the touchscreen, navigate to Menu > Samples, create a sample card, and make sure the device
functions properly and the sample looks correct. If the tipping is uneven, see 99875607
ExpressCard 2000 Hardware Service Manual for steps to calibrate the tipper module.
17) Return the tipper heater and report form (including number of cards tipped) to MagTek for recycling.
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