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ExpressCard 2000 Hardware Service Manual

1. Cad Personals System Hardware Senice anual Page 142 5 Adjustments 10 Press the DK button at the bottom of the rouchkit USB Controller window to close it 55 Use CEE 3 Genel Seting Tao tdge Conpenseten Hardnere About Linaaizaten Cuve Pein De 4 pants diaman to match eplan Catan Clear and Deerineaizaton paamete and do 4 points Caltiale Do3 pantsineaicaton er bete touchscreen ear Do cha test to verty the touch accuracy Draw Test y i Em 5 2 How to Calibrate the Hopper Transport Module The Hopper Transport keeps several settings that tell it how far to go when it moves from one place to another Ifthe Hopper Transport needs to be adjusted follow the steps in this section 5 2 1 How to Callbrate Hopper Transport Home to Printer Handoff calibrate the Y position of the Hopper Transport during handoff to printer from hopper 1 follow these steps 1 Remove hopper 2 and hopper 3 from the EC2000 and set them aside 2 From the ExpressCard 2000 Utility navigate to Menu gt Settings gt Service gt MCP Commands to open the Controller Commands page 3 Press the Shuttle Home button 4 Inthe dropdown list next to the To Hopper button select Hopper i 5 Press the fo Hopper button 6 Press the Push to Roller button 7 Press the Shuttle to Printer button 8 Check to make
2. Wheel Motor Top Clamp Motor Bottom Clamp w Gum D ma C 1 per Move Al Fast Set Emboss Hold r Time amp Helghe AI Motors 100 Do Not Move Bottom Bonom Close Clamp Counter Clockwise Clockwise Figure 2 5 Embosser Utility Page The Steps Direction box specifies how many steps the motor will take when you press any of the 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 page to perform specific operations 2 9 3 2 How to Move the Embosser Dalsy Wheel The daisy wheel driven by the button contains the set of characters the embosser 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 daisy wheel a full 360 degrees move it 80 characters 20 steps per character 1600 steps To move the daisy wheel follow these steps from the Emboss r UU page 1 Tum on the Move At Fast checkbox The daisy wheel is designed and tested to operate at fast speed y wheel to take see section 2 9 3 1 About the Embosser Page and press the button 2 Set the number of steps you want the Uti 3 Repeat the moves as nece
3. Figure 3 6 Run a Thin Bead of Tri Flow Along the Top of the Shaft TOP LEFT VIEW 7 Use the drive belt to move the XY transport to the front of the device then to the rear again to spread the Tri Flow along the length of the shaft see section 2 8 How to Safely Move Transports By Hand 8 ME you have applied too much Tri Flow to the shaft some may drip off the shaft If this happens dab off the excess with a clean lint free cloth pre 000 Ielantlsusmcs Cani Personalizar System Hardware Senice anual Page 35 Preventive Maintenance 3 8 Service the Exit Transport Module No additional service is necessary for the Exit Transport other than the roller cleaning described in section 3 3 Clean All Transport Rollers 3 9 the Tipper Heater Power Down the Device D 4 5 Navigate to anu gt Bettings Tipper to open the Tipped pas Press the Bet Heater OFF button to turn off the tipper heater Note the value under Current Tipper Temp Ifthe tipper temperature is 50 C or hotter the tipper heater is not safe to touch 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 Power down the device 000 Ielantlsusmcs Cad Personalizar Stam Hardware Senice anual Page 36 3 Preventive Maintenance 3 10 Clean Inside the Device
4. re install the embedded PC s SSD follow these steps 1 Insert the SSD into its slot at a slight incline The end opposite the connector should be slightly higher than the end that goes into the connector as shown in Figure 4 101 2 Use the No Philips screwdriver to insert and tighten the two screws that secure the SSD 3 Reinstall the embedded PC by reversing the steps you followed to pull it out partway Use section 4 15 How to Remove Re install the Embedded PC as reference Depending on the situation it may be necessary to perform additional sofiware or hardware configuration steps as directed by your reseller MagTek Support Services or MagTek Engineering BEFORE powering up the device 4 Perform any additional service that requires the device to be powered off and open 5 Close the top access door 6 Re attach the power cable network cable and any security hardware 7 Powerup the device 8 From the touchscreen navigate to Menu create sample card and make sure the device functions properly and the sample looks correct GODS Wan issuance Cari Fersonalion System Radar Serves anual Page 121 4 Removal and Re installation 4 17 How to Remove Re install the Main Logic Board MLB Approximate time to remove 5 minutes plus any sub procedures Approximate time to re install 5 minutes plus any sub procedures The main logic board MLB drives the device s motors and communica
5. Semis Manual Page 40 Preventive Maintenance Figure 3 9 Bad Embosser Wheel Alignment Figure 3 8 MAGNIFIED 6 Ifany cones are broken or bent replace the characters in the same location if possible If replacement is not feasible cut off the top and bottom tines using the diagonal side cutters remove the character from the tines and install it to another set of tines and re map the character to another tine alter preventive maintenance is complete and the device is powered up see section 4 10 How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 7 Check the daisy wheel alignment by standing in front of the device and looking straight down at the embosser Use an inspection mirror as shown in Figure 3 8 so you can see the cone on the bottom of the current character and the hole in the embosser hammer Figure 3 9 shows a cone and hole that are not properly aligned 8 Check embossed character heights using the steps in section 5 4 How to Calibrate the Embosser and adjust them if necessary to account for normal wear Pay special attention to any characters you have replaced or re mapped Egress GODS Wan ac Cari Serves anual Page 41 3 Preventive Maintenance 3 13 Service the Electronics Visually inspect all wires and cables checking for insulation breakage or wear on moving cables 3 14 Service the Cover After completin
6. sag Card at image printer input is ejected to image printer exit 2000 lesance Card Pesonalaation Sytem Nardware anual Page 13 2 Introduction Press This Button Verify This Happens X carriage clamps card at printer exit 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 Embosser wheel moves to first character on wheel look for empty tines next to the tine that is currently between the hammers XY Transport moves card out of printer and to embosser ardHomeXY XY Transport moves card so its lower left corner is between embosser tines XY Transport moves card to Exit Transport s input rollers X carriage s clamp releases the card Exit transport raises its bottom roller rolls for a short period of time Ramp fan turns on Card goes into Card Rejection Bin LII Exit Transport rolls card to exit ramp ramp fan tums on briefly 20000 Teta Cani Personalizar System Hardware Senice anual Page 14 2 Introduction 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 gt gt Bensors o open the Sensor page In normal operation with the top access door closed with all card stoc
7. Controller Commands Cisse Tabasa oa Senes vane Pussertiome p pee pem After successfully calibrating press the Bava button to save the new embosser wheel center value Press the DK button to dismiss the popup window confirming it has been saved Open the top access door and inspect the embosser tine position to make sure the currently selected tine is centered in the embosser bridge opening Press the Status button to return to the Btatus page Egress Cari SM Hardware Serves anual Page 150 5 Adjustments 5 4 3 How to Measure Embossed Character Thickness Figure 5 6 Measuring Embossed Character Height When the sections below call for creating and measuring tuning card follow these steps 1 From the touchscreen navigate to Menu gt Settings gt Tuning to open the Tuning Mava Embossing pace 2 Press the Prinijbution The EC2000 will create tuning card and drop n the card output hopper 3 Inserta blank portion of he card into the calipers and gently tighten the knob 4 Press the ZERO button or equivalent to rese the zero point of the calipers to the card thickness 5 Loosen the calipers and move it to the embossed characters you want to measure Figure 57 Font IDs 6 Gently tighten the calipers and read the thickness of embossed charact
8. 190012 2X Figure 4 85 Tipper Exit Ramp Module FRONT LEFT VIEW To remove the tipper exit ramp module follow these steps 12 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected pred 20000 Ielantlausncs Cari Pernnalzston System Hardware Senice anual Page 106 4 Removal and Re installation 13 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 14 Remove the cover by following the steps in section 4 4 How to Remove Re install the Cover 15 Disconnect the tipper heater plug on the left side of the tipper module see Figure 4 86 Figure 4 86 Tipper Heater Connector TOP VIEW FROM FRONT 16 Unplug the top motor connector on the left side of the tipper module see Figure 4 87 Egress ance Cari Personalan SM Hardware Serves anual Page 107 4 Removal and Re installation Figure 4 87 Tipper Top Motor Connector FRONT VIEW 17 Remove the four sets of screws and washers that secure the module to the top deck plate shown in Figure 4 85 18 Use both hands to pull the tipper module toward the front of the
9. if testing EC2000 with Front Indenter installed Front white indent cartridge moves out of embosser toward rear of device Cariridge Load indenter Move Only if testing EC2000 with Front Indenter installed Front white indent cartridge moves back into embosser Cartridge indenter Move Only if testing EC2000 with Front Indenter installed Front white indent cartridge moves back into or stays in embosser Cari to Indeni Only if testing EC2000 with Front Indenter installed Front white indent cartridge moves between letters on embosser wheel Ribbon Advance if testing EC2000 with Front Indenter installed Ribbon in front white indent cartridge advances by about 7 Push To Roller Hopper transport s wheels tum for a few seconds Hopper transport takes a card from current hopper Hopper transport moves to image printer SE E jor Hom Hopper transport s wheels turn for a few seconds to feed card into image printer Press Printer Ejeet button to move card through image printer XY Transport moves to rear left of device XY Transport s X carriage moves to the left Y XY Transport s Y transport moves to the rear of the device XY Transport moves to image printer XY Transport s X carriage moves toward image printer to engage with card X carriage s card clamp rotates to unclamped position
10. 3 Preventive Maintenance 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 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 button to open the Fig 3 Inthe ersion Information li age note the Controller Firmware and Printer Firmware entries Help Sanat BI7ECAB sion Information Aplication Version MTECUM 1216 1 0 0 6 MTECJobSenver exe 20034 EE eoa 20010 EI QO webs di 10357514560 Go His RTS Device Info Status Men Offline 4 Press the Men button to launch the Main Menu page 5 Press the bution to launch the Settings Menu page 6 Press the button to launch the Firmware Download password page 7 Use the on screen keyboard to enter the password then press the E key to launch the second password page 8 Use the on screen keyboard to enter the password then press the E key to launch the page 9 No
11. Adjustments These steps may be necessary after installing a new tipper module or alter updating software firmware or drivers Re calibration may also be used to compensate for normal tipper platen wear The EC2000 s tipper settings may show 0 for the Tipper Fan Delay value but it the setting shown may not be accurate Fix the value send it to the main logic board by doing the following 1 Navigate to Menu gt Betiings Tipper to open the Tipper page 2 Select the Fan Delay value Even if it already says 0 select it and set it to 0 again 3 Press the Bave button 1 Make sure there is foil in the tipper foil cartridge see 99875600 ExpressCard 2000 User Installation and Operation Manual for detailed instructions Be sure you have offered to give the customer any used tipper foil rolls for secure storage or disposal before using them 2 Create a tipped sample card from Menu gt Samples 3 Remove the tipper foil cartridge for examination 4 Examine the negative image of the card imprinted on the foil You will see a rectangle where the top line was created by the top of the tipper heating element the bottom line was created by the bottom of the tipper heating element and the text is somewhere between The text should be centered up and down between the two lines the lines are traced in red in Figure 5 10 Figure 5 10 Embossed Characters Centered In Tipper OOO Ielantlsusncs Cad
12. Removal and Re installation Figure 4 89 Tipper Breakout Board FRONT VIEW 20 Use both hands to remove the tipper module from the device and set it aside making sure there are no cables caught on it re install the tipper and exit ramp module reverse the steps for removing it making sure not to squeeze any wires between the module and any other parts in the device To identify which cables go to which connectors use the labels near the end of each cable Figure 4 88 and Figure 4 89 In some cases you may want to trace the cable back to the motor or sensor it is connected to After re installing the module follow these steps D 2 3 4 5 7 Perform any additional service that requires the device to be powered off and open Re install the cover and top access door by following the steps in sections 44 and 4 2 respectively Re install the tipper foil spool assembly with the original tipper foil roll or obtain and install a new one from the customer Close the top access door Re attach the power cable network cable and any securi Power up the device From the touchscreen navigate to Menu gt create a sample card and make sure the device functions properly and the sample looks correct hardware Egress GODS Wan issuance Cari System Hardware Serves anual Page 110 4 Removal and Re installation 4 14 How to Remove Re install the Exit Transport Module
13. The Bangs 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 Manu page by pres Barvice button to open the Bervice Menu page For example you can use the Sensor Utility page to view the status of the EC2000 s sensors or use the MGP 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 2000 individually rather than as part of a standard sequence use the touchscreen to navigate to Menu gt Settings Service gt MCP Commands to open the Eommands 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 21 Controller Buttons and Corresponding Movements Press This Butt
14. missing characters on other tines and re map them after preventive maintenance is complete and the device is powered up see section 4 10 How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 4 Inspect the characters on the top embosser wheel to identify any broken or bent cones Top side replacement font sets include a 33070077 FUN TYPE FARRINGTON F7B EMBOSS DIE b 33070079 FUN TYPE GOTHIC ALPHA EMBOSS DIE ZERO OH c 33070181 FUN TYPE GOTHIC NUMBER EMBOSS DIE d 33070183 FUN TYPE GOTHIC SPECIAL CHARACTERS EMBOSS DIE e 33070516 FUN TYPE FRONT INDENT SANS SERIF 12PT f 33070524 FUN TYPE INDENT HELVETICA 2 33070546 FUN TYPE FRONT INDENT SANS SERIF 14PT h 33070581 FUN TYPE TURKISH EMBOSS DIE 0 33070075 FUN ANVIL REAR INDENT 5 Use the inspection mirror and flashlight to inspect the characters on the bottom embosser wheel to identify any broken or bent cones see Figure 3 8 and Figure 3 9 Bottom side replacement font sets include a 33070078 FUN TYPE FARRINGTON F7B EMBOSS PUNCH b 33070080 FUN TYPE GOTHIC ALPHA EMBOSS PUNCH ZERO OH c 33070081 FUN TYPE REAR INDENT MC ZERO d 33070182 FUN TYPE GOTHIC NUMBER EMBOSS PUNCH 33070184 FUN TYPE GOTHIC SPECIAL CHARACTERS EMBOSS PUNCH f 33070582 FUN TYPE TURKISH EMBOSS PUNCH 2 33070608 FUN TYPE FRONT INDENT BANK ID NUMBER h 33070074 FUN ANVIL FRONT INDENT Egress 30 Wan ance Cari
15. 624 8350 888 415 6800 Email support magtek com Technical Support For technical support for the ExpressCard 2000 within the United States contact Mag Tek Support Services by phone or ema Ifyou are outside the United States contact your local sales representative AppendixB _ Glossary Term Definition DHCP Dynanic Host Configuration Protocol C2000 ExpressCard 2000 MK Tssuer Master Key for EVES generation K Panel nares ofa multicolored Ribbon e YMCK that contains Back resin for transfert the card surface Also used in reference to the application of preference to images printed on the card those using the black panel in of process YMC black DES Master Key for Personalization MCP MagTek Control Protocol MLB Main Logie Board MSR MagnePrint Swipe Reader c Abbreviation for polyvinyl chloride often called vinyl PVC isa component ofthe 0 002 tick clear dye receptive film on the surface of the identification card and is the primary ofthe identification card cores Returned Cards A card that has beca issued toa card holder and returned for cf taxing SS Secure Sockets Layer SSL protocol Originally developed Netscape SSL hasbeen universally accepted onthe Workd Wide Web for authenticated and encrypted communication between cliens and servers USE A LSMsee I2Mbiuse serial communication interface that can support 127 separate devices consisting o
16. Caution Do not use alcohol wipes liquids or chemicals on the touchscreen Clean the device in phases to avoid blowing dirt dust or debris into sensitive components 1 Remove all remaining consumables from the device stock cards image printer ribbon indent cartridge s tipper foil ete and set them aside in a secure location or give them to the customer for temporary storage or secure disposal 2 If there is a large visible amount of dirt dust or debris in the device wipe the worst of it out with a clean dry cloth Wipe remaining dirt dust and debris off the base plate and main components with alcohol wipes 4 Used compressed air to blow out any remaining dirt dust or debris from between components and re wipe as necessary 5 Use compressed air to clean each of the sensors see section 2 9 2 How to Use the Sensor Utility Page for an inventory of all sensors in the device 6 Use compressed air to clean out the electronics in the bottom between the side access doors with special attention paid to the power supply in the rear left comer Egress GODS Tan ance Card Fersonalion Sam Hardware Serves anual Page 37 3 Preventive Maintenance 3 11 Service the Image Printer Module Follow these steps to service the image printer 1 Make sure the interior of the EC2000 is clean see section 3 10 Clean Inside the Device Performing image printer maintenance with dirt or debris inside the cover may damage the p
17. Config to open the Eonfiguration Editing password page b Enter password 1234567 then 7654327 to open the Configuration Editing page c Scroll to the Embosser gt CamAdjustments section Configuration Editing Canadien Tangan Cange Fort d Repeat these steps for the FontID1 CamAngleTop FontID1 CamAngleBottom FontID2 CamAngleTop FontID2 CamAngleBottom FontID4 CamAngleTop and FontID4 CamAngleBottom 6 settings total i Select the number below the name of the value A keypad will appear on the right side of the 20000 Ielantlsusncs Cani Personalizar System Hardware Senice anual Page 152 5 Adjustments gt Forno OSD ii Press the E button to clear it the value above the keypad to 0 iii Enter 60 on the keypad then press the E button to change the setting iv Repeat these steps for the next setting until you finish with Fontib4 CamAngieBottom e Repeat the steps above to set FontID3 CamAngleTop and FontID3 CamAngleBottom to f Press the Bave button to save all changes Configuration Editing sonra E Tu 4 Press the DK button to dismiss the popup confirming the values have been saved 54 5 Howto Set Minimum Thickness Using CamAngle The embosser must produce a minimum thickness before it makes sense to use knuckle adj
18. Disengage and lean back the top access door by following the steps in section 42 How to Remove Re install the Top Access Door up to the point where the top access door is leaning up and back behind the device Figure 4 3 4 Remove the image printer ribbon and set it aside in a secure location or give it to the customer for temporary storage or secure disposal 5 Move the hopper transport away from the image printer toward the front of the device see section 2 8 How to Safely Move Transports By Hand 6 On the rear right side of the image printer locate the power cable shown in Figure 4 52 Remove any adhesive securing it to its connector and disconnect it Figure 4 52 Image Printer Power Connector FRONT RIGHT VIEW 7 From the power connector look left across the rear wall of the EC2000 past a motor to a circuit board with several white connectors Find connector J31 on the circuit board and unplug the black insulated cable from it see Figure 4 53 and Figure 4 56 This is the image printer USB cable Figure 4 53 Image Printer USB Cable Connected to J31 TOP VIEW FROM REAR 30 san ace Cari POTEET System Radar Serves anual Page 78 4 Removal and Re installation Near the front left screw of the image printer locate the cable labeled Y END SENSOR shown in Figure 4 54 and disconnect it Figure 4 54 Image Printer Exit Sensor Connector TOP LEFT VIEW 9 Use the 5 32 Allen w
19. Embossed and Printed Characters In this tuning procedure you will need to notice subtle differences in alignment between embossed characters and the ink on top of them The easiest way to do this is to lay the card flat at eye height so you are looking at the character from the edge of the card and note how light or dark the character looks Then turn the card around and note how light or dark the character looks from the other side The lighter looking side is the side the embossed text needs to move AWAY from For example if the right side looks darker the embossed character is too far to the left To change calibration values on the EC2000 Tuning pages select the New field next to the value you want to change then use the up and down arrows to adjust the value If you want the value to move in larger or smaller amounts when you press the arrows press the N per tap button between the arrows Egress 2000 san tance Cari Stam Saves Manual Page 158 5 Adjustments Follow these steps to tune the embosser so embossed characters are aligned with printed characters 1 Install the type of image printer ribbon you want to calibrate with Embosser tuning can be ribbon specific so you should repeat this procedure for every type of ribbon that will be used in the device See section 1 1 Required Tools for a complete list of ribbons 2 Close the top access door 3 Navigate to Menu gt Settings gt Tu
20. Map to open the first Eharacter Mapping password page 5 Enter password then press the E key to open the second Character Mapping password page 6 Enter password then press the to open the Character Mapping pase 7 Use the From Current dropdown list to select the old tine where the character was installed 8 Use the Fo 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 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 Ifthe character is still on the old tine uninstall t 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 gt Bettings gt Serviee gt Char Map to open tbe first Eharacter Mapping password page 4 Enter password then press the to open the second Character Mapping password page 5 Enter password then press the E key to open the page 6 Use the From Current Tine dropdown list to select the tine where the character was installed 7 Press the Eleaf button Repeal the above steps for any additional characters you nee
21. Time amp Heighi 2 Press the button to refresh the settings shown in the list box 3 Select the tine you want to change in the Fine 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 Hola 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 charac hange the setting The EC2000 will add this value to the device s global nd EmbossAngleBottom settings EERE a ings 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 Bave All button to save the settings for all ines 7 Press the Status button to return to the Biatus page 20000 Ielantlsusncs Ca
22. Y position of the Hopper Transport during handoff to the printer from the manual feed slot follow these steps 1 Make sure hopper 2 and hopper are removed from the EC2000 2 From the ExpressCard 2000 Utility navigate to Menu gt Settings gt Service gt MCP Commands to open the Eontroller Commands page 3 Press the Shuttle Home button 4 Press the fo Manual Feed button 5 Insert a blank card into the manual feed slot with its magstripe facing down and to the right The slot will not automatically take the card 6 Press the Roller Consume button 7 Press the button 8 Check to make sure the curd is centered at the opening of the image printer 9 Ifthe card is centered at the printer opening press the Roll to Printer button 10 Ifthe card is not centered at the printer opening or if it hit either side of the printer opening or if the card skewed to one side when entering the printer a Pull on the triangular belt on the front side of the hopper transport to back the card out of the hopper transport and remove the card b Navigate to Menu gt Settings gt Edit Config to open the Eonfiguration Editing password page Enter password then press the E button d Enter password then press the E button to open the Eonfiguration Editing pase Scroll through the list of options to find the ShuttleHomeToExceptionFeed setting and select the number beneath it to bring up the on screen keypad 0 hopper transport
23. 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 the field service laptop to make sure its browser and network connection are functional 22 Important Safety Information The information in this document is intended for use by trained professional service personnel only I 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 Ac For your personal safety and to prevent damage to the device disconnect ACAUTION Fe l safety and he device di power from the ExpressCard 2000 before you connect or disconnect any cable electronic board or assembly 2 3 How to Handle ESD Sensitive Parts 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 ete 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 th
24. along its edge accessible see Figure 4 94 While pulling use a flashlight and other tools as appropriate to make sure its cables do not snag inside the device Figure 4 94 Connectors On Right Edge of the Embedded PC TOP VIEW FROM RIGHT 6 Disconnect all the cables connected along the right edge of the embedded PC plus the power connector near the front edge The connectors are shown in Figure 4 95 20000 Ielantisusncs Cani Peronalzston System Hardware Senice anual Page 114 4 Removal and Re installation dge of Embedded PC TOP VIEW FROM RIGHT Figure 4 95 Connectors Near Right 7 Slowly and carefully continue to pull the embedded PC out further until you can see the remaining cables connected to its left half as shown in Figure 4 96 While pulling use a flashlight and other tools as appropriate to make sure its cables do not snag inside the device 8 Support the embedded PC with your hand or on the tabletop while completing the final steps Figure 4 96 Embedded PC Left Edge Visible TOP VIEW FROM RIGHT 9 Disconnect the remaining cables see Figure 4 97 including at least two ribbon cables connected to COMI and COND and one ribbon cable connected to the multi colored front panel connector If there is silicone adhesive holding any of the connectors remove it completely 00D Cani Peronalzston System Hardware Senice anual Page 115 4 Removal and Re in
25. device several inches to give room to disconnect the cables plugged in to the breakout circuit board mounted lo the exit transport module behind it see Figure 4 88 Pay careful attention to any nearby wires as you pull it forward pret Cani Personalzston System Hardware Senice anual Page 108 4 Removal and Re installation Figure 4 88 Breakout Board Behind Tipper and Exit Ramp Module TOP VIEW FROM FRONT 19 Disconnect the following connectors from the breakout board behind the tipper working from the left side of the device to the right side Use Figure 4 89 as a reference and keep track of which cable connected to which connector a From connector J4 on the board disconnect the Tipper Foil Advance Motor cable b From connector J3 on the board disconnect the Tipper Cog Grip Motor cable c From connector J15 on the board disconnect the Tipper RTD cable d From connector J14 on the board disconnect the Tipper Heater cable From connector J17 on the board disconnect the Tipper Foil Advance Hall Sensor cable f From connector J12 on the board disconnect the Exit Fan cable 2 From connector J8 on the board disconnect the Tipper Card Grip Sensor cable h From connector J7 on the board disconnect the Tipper Cam Home Sensor cable i From connector J9 on the board disconnect the Tipper Card Exit Sensor cable prea Cad PETRIE System Hardware Senice anual Page 109 45
26. first few steps in section 4 15 How to Remove Re install the Embedded PC 5 Disconnect the plug that connects the embedded PC s COM port to the power controller as shown in Figure 4 108 Figure 4 108 Embedded PC Communication Input from Power Controller RIGHT VIEW 6 Disconnect the plug that connects the embedded PC s power input to the power controller as shown in Figure 4 109 Figure 4 109 Embedded PC Power Input from Power Controller RIGHT VIEW 7 Use the 5 64 Allen wrench to remove the five screws that secure the hopper deck plate to the hopper module and carefully move the hopper deck plate out of the way to access the right connector panel underneath it see Figure 4 110 pre 00D TTA PETRIE System Hardware Senice anual Page 126 4 Removal and Re installation Figure 4 110 Right Connector Panel Below Hopper Deck TOP VIEW FROM FRONT 8 Unplug all four connectors from the right connector panel noting which cable connects where 9 Locate the left connector panel near the exit transport and behind the embosser see Figure 4 111 Figure 4 111 Left Connector Panel TOP VIEW FROM FRONT 10 Unplug all five connectors from the left connector panel noting which cable connects where 11 Behind the left side access door locate the power controller indicated in Figure 4 112 pret 20000 Teta TRU Cani PEATE System Madnar Senice anual Page 127 4 Removal and R
27. in front of the input wires 7 With 8 Replace the left side access door by following the steps in section 4 3 How to Remove Re install the Side Access Doors 9 Perform any additional service that requires the device to be powered off and open stance carefully tip the device forward to its normal operating position 10 Re attach the power cable network cable and any security hardware 11 Power up the device 12 From the touchscreen navigate to Menu gt create sample card and make sure the device functions properly and the sample looks correct Ifthe device does not power up or function properly contact MagTek Support Services see Appendix A Technical Support 20000 Ielantlsusncs Cad PETRIE System Hardware Senice anual Page 135 4 Removal and Re installation 4 20 How to Remove Reinstall the Magnetic Stripe Reader MSR Module Approximate time to remove 5 minutes plus any sub procedures Approximate time to re install 15 minutes plus any sub procedures The magnetic stripe reader MSR provides device operators a way to swipe cards with magnetic stripes and transmit the card s data to the embedded PC It is located in the slot at the top front center of the device just above the MagTek logo To remove the magnetic stripe reader follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re i
28. instructions to replace the image print head see 99875600 EC2000 User Installation and Operation Manual ET 00D Ielantlsusncs Personalizar System Hardware Senice anual Page 76 4 Removal and Re installation 4 7 Howto Remove Re install the Image Printer Module Approximate time to remove 15 minutes plus any sub procedures Approximate time to re install 15 minutes plus any sub procedures The image printer located in the rear center of the device takes blank card stock from the hopper transport encodes any required data onto the card produces images on both sides and ejects the card out the other side to be retrieved by the XY transport 33070818 46500185 4x 48325000 4X j 48825000 Figure 4 51 Removing Re installing the Image Printer FRONT RIGHT VIEW Follow these steps to remove the image printer module 1 If you are replacing any modules that do NOT require silicone adhesive replace those first That will reduce the risk of breaking the image printer power connector s adhesive during other service 2 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected GODS san ance Stem Radar Serves anual Page 77 4 Removal and Re installation 3
29. list pressing the C button then entering the new number on the on screen keypad and pressing the E button Adjust about 10 steps at a time IF the card is off center from the green roller and is too close to the front of the EC2000 increase the ExitHandoffAdjustmentY setting by clicking the number in the list pressing the E button then entering the new number on the on screen keypad and pressing the button Adjust about 10 steps at a time If the card is off center from the green roller and is too close to the back of the EC2000 decrease the ExitHandoffAdjustmentY setting by clicking the number in the list pressing the EJ button then entering the new number on the on screen keypad and pressing the button Adjust about 10 steps at a time Press the Save button to save your changes Repeat these steps from step 1 until the card clamps correctly when it exits the printer 9 Navigate to Menu gt Settings gt Service gt MCP Commands to open the Controller Commands page 10 Press the bution to release the card 11 Press the Exit Ejeet button to eject the card into the cand output hopper 12 Press the Status button to retum to the Status page 54 541 How to Calibrate the Module About Embosser Calibration The EC2000 embosser squeezes cards between two knuckles Each knuckle can be adjusted higher or lower to make sure embossed characters are being pressed deeply enough into the car
30. looking only at the last character of the ong string of Tete at the bottom of the test card 15 Repeat the same process for Font ID3 if installed looking only at the last character of the string of front indented characters 16 Repeat the same process for Font ID4 looking only at the last character of the sting of digits on the rear of the test card 17 Press the Bet Default button to save the settings as defaults Enter the setup passwords 18 Write down the settings for the current ribbon on the rear of the manufacturing checklist then repeat the process for all ribbon types that will be used in the EC2000 YMCKO YMCKOK ct After replacing the ribbon start by setting all values on the Tuning Move Embossing and pages to the same values as the previous ribbon Only small fine tuning to existing values may be necessary 5 5 How to Calibrate the Indenter Module 5 5 1 About Calibrating the Indenter Module The rear indenter module in the EC2000 s embosser moves between three positions LOAD position During normal operation it is parked below the embosser HOME position During rear indent operations it moves out of the embosser and places the ribbon between the characters on the embosser wheel UNLOAD position When removing the indent cartridge it moves all the way out for easy removal If the indent ribbons are aligned such that indented characters are too far toward one edge of the indent
31. 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 gt Settings gt Bervice gt MCP Cmds to open the Eontroiier 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 3 Feed the card partly into the hopper transport and press the Faller Consume button Hold the card there until the rollers stop moving ST 2000 Tan issuance Cari System Radar Serves anual Page 25 Preventive Maintenance Figure 3 1 Cleaning the Hopper Transport Rollers TOP VIEW FROM FRONT b Feed the card partly into the left
32. may need to be re adjusted 23 Test the new hopper module manually by moving the hopper transport along the full range from front to back see section 2 8 How to Safely Move Transports By Hand Make sure it does not touch any cables or other parts along its entire path that the drive motor at the rear of the device moves along with it and that it does not make any unusual sounds such as clicking rubbing or grinding 24 Perform any additional service that requires the device to be powered off and open 25 Re install the cover and top access door by following the steps in sections 44 and 4 2 respectively 26 Move the hopper transport to the front of the device just past hopper 7 and before it rotates to the manual feed slot see Figure 4 31 and section 2 8 How to Safely Move Transports By Hand 27 Re install the card stock hoppers 28 Close the top a 29 Re attach the power cable network cable and any security hardware 30 Power up the device 31 Perform any relevant adjustments from section Adjustments notably sect Calibrate the Hopper Transport Module 32 From the touchscreen navigate to Menu gt create sample card and make sure the device functions properly and the sample looks correct ss door n 5 2 How to pear 00D ETE Personalizar System Hardware Senice anual Page 75 4 Removal and Re installation 4 6 Howto Remove Re install the Image Print Head For detailed
33. replacement hopper module move the hopper transport to hopper 4 see section 2 8 How to Safely Move Transports By Hand Using both hands carefully insert the rear side of the hopper module into the device at a slight angle and rest it on the top deck plate so its screw holes line up with the corresponding holes in the top deck Make sure it doesn t pinch any cables or the drive belt See Figure 4 39 Figure 4 39 Re installing Rear Side of Hopper Module First TOP FRONT VIEW 4 Carefully lower the front side of the hopper module into the device so its holes line up with the corresponding holes in the top deck plate Make sure it doesn t pinch any cables or the drive belt See Figure 4 40 Figure 4 40 Re installing Rear Side of Hopper Module First TOP FRONT VIEW 5 Pull any loose cables toward the outside of the device to make them easy to find and to clear them out of the way 2000 santlsusncs Cad Personalzston System Hardware Senice anual Page 68 4 Removal and Re installation 6 Move the hopper transport to the front of the device just past hopper 7 and before it rotates to the manual feed slot see Figure 4 31 and section 2 8 How to Safely Move Transports By Hand 7 Stick 7 of double stick tape to the hopper transport cable just behind the plug 8 Plug the flex cable into the hopper transport so it points toward the rear of the device and stick the double stick t
34. side of the exit transport and press the Exit Ejeet 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 Feed the card partly into the right side of the exit transport and press the Exit Rejeci button Push inward to keep the card from being pushed out until the rollers stop moving Cad Personalzston System Hardware Senice anual Page 26 3 Preventive Maintenance Figure 3 3 Cleaning the Right Side of the Exit Transport TOP VIEW FROM FRONT 4 Feed the card partly under the exit ramp rollers and press the EX Ejec 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 bution to return to the Btatus 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 20000 Ielantlsusmce Cani Personalizar System Hardware Senice anual Page 27 Preventive Maintenance 3 4 Update the Software If MagTek Support Services has supplied files to apply EC2000 software patches follow these steps to install them D 3 4 6 8 Use the Ethernet cable to connect the service laptop to the EC2000 If necessary you may instead use the customer s instant
35. sure the card is centered at the opening of the image printer 9 If the card is centered at the printer opening press the Roll to Printer button prea OOO Weta TRU Cari PEATE System Hardware Senice anual Page 143 5 Adjustments 10 Ifthe card is not centered at the printer opening or if it hit either side of the printer opening or if the card skewed to one side when entering the prin 3 Pull on the triangular belt on the front side of the hopper transport to back the card out of the hopper transport and remove the card b Navigate to Menu gt Bettings Edit Config open the Configuration Editing password page c Enter password 1234567 then press the E button d Enter password 7654321 then press the E button to open the Editing page e Scroll through the list of options to find the ShuttleHomeToPrinterHandoff setting and select the number beneath it to bring up the on screen keypad f If hopper transport was too far toward the rear of the EC2000 increase the setting press the Bave button and to back to the beginning of this section 3 IF hopper transport was too far toward the front of the EC2000 decrease the setting press the Bave button and go back to the beginning of this section 11 Press the Printer Ejeet button 12 Remove the card from the image printer exit and recycle it 5 2 2 How to Calibrate Hopper Transport Manual Feed Slot to Printer Handoff calibrate the
36. the X left right position of the image on the card by following these steps Use the Rx command to read the current setting for the X position b Use the Px jnumber command where number is 1 4 steps smaller than the X value reported by Rx to bring the left edge of the image closer to the left edge of the card Create a set of test cards that represent the full range of the application s images d test cards are created successfully repeat the process of lowering the X position e Ifthe ribbon breaks or the printer produces blank cards raise the value closer to where it was to start and re try test cards until they are created successfully 6 Increase the X size length of the image on the card by following these steps 3 Use the Ral command to read the current setting for the X size b Use the Palj jnumber command where number is 1 4 steps larger than the original value reported by Ral to add rows to the right edge of the image bringing it closer to the right edge of the card Create a set of test cards that represent the full range of the application s images d test cards are created successfully repeat the process of increasing the X size e Ifthe ribbon breaks or the printer produces blank cards ower the value closer to where it was to start and re try test cards until they are created successfully 7 Raise the Y up down position of the image on the card by following these steps 3 Use the Ry command to
37. tighten the left and final screw 6 Re clip or re tie the MSR cable to the cover 7 Perform any other service that requires the device to be powered off and open 8 Close the top access door 9 Power up the device 10 Test the device Note the other end of the MSR cable connects to the embedded PC at the location shown in Figure 4 124 see section 4 15 How to Remove Re install the Embedded PC for more information about the embedded PC You should not have to replace the cable during standard MSR replacement Figure 4 124 Magnetic Stripe Reader Connector to Embedded PC TOP VIEW FROM REAR Egress GODS Wan ace Cari Fersonalion SM Hardware Serves anual Page 137 4 Removal and Re installation 4 21 How to Remove Re install the Touchscreen Approximate time to remove 5 minutes plus any sub procedures Approximate time to re install 5 minutes plus any sub procedures The touchscreen presents device operators and service personnel with a graphical user interface It has a bidirectional data connection with the embedded PC which transmits video for display and receives mouse commands when a user presses on the screen It is mounted to the front center of the cover E Figure 4 125 Cover and Touchscreen REAR RIGHT VIEW ROTATED To remove the touchscreen follow these steps 1 If you are replacing any modules that do NOT require silicone adhesive replace those first Th
38. to Fine Tune Embossed Character Helght Using Software If the embossed character height of the last card is between 0 0180 in and 0 0190 in the embosseris calibrated skip this section Otherwise to perform fine adjustment of embosser character thickness follow these steps 1 Create and measure a tuning card 2 Make sure the embossed character thickness is between 0 0170 in and 0 0190 in by following the steps in the previous sections 3 Inthe ExpressCard 2000 Utility navigate to Menu gt Settings gt Edit Contig open the Eonfiguration Editing password page 4 Use the onscreen keypad to enter password and press the E ey 5 Use the onscreen keypad to enter password 684321 and press the E key 6 Scroll through the settings list to find CamAngleTop and CamAngleBottom Egress GODS san issuance Cari Fersonaion Stem Hardware Semis Manual Page 155 5 Adjustments Configuration Editing Configuration Editing Menu 7 M most of the FontID1 embossed character thicknesses are less than 0 0180 in increase the thickness 3 Select FontID1 gt CamAngleTop add 10 to the current setting enter the new value in the text entry box at the top right of the screen and press the E key b Ifthe latest tuning card was slightly concave down frowning around FontlDI leave FontID1 gt CamAngleBottom setting as it is Otherwise select FontID1 gt CamAngleBottom add 10 to
39. to the right of the printed character decrease the X SPI value and press the large Bave bution IF the embossed character appears higher than the printed character decrease the Y SPI value and press the Bei button then the Bave button IF the embossed character appears lower than the printed character inerease the Y SPI value and press the rd then the Bave button h Press the Back button to return to the page i Repeat the process until the embossed character lines up with the printed character Look at the LAST letter at the bottom of the card Adjust X SPI Y SPI E DI D x SPI ndi Yn Egress GODS Tan issuance Cari Fersonalion System Hardware Serves anual Page 161 5 Adjustments SPI Finished TX SPI 8 Decrease the Card X Offset setting by T and allow more room to adjust the individual fonts This provides about 10 more steps that each Font ID can move further to the left if needed 9 Calibrate the Font IDI X Offset and Font IDI Y Offset settings which changes the position of Font mm a Press the Primi button The EC2000 will create a test card using every available font ID b Look only at the first character of the PAN Font IDI from all angles and determine whether the embossed character is to the left righ above or below the printed character c Ifthe embossed character appears to the left of the
40. was too far toward the rear of the EC2000 decrease the setting press the Save button and to back to the beginning of this section pret 20000 Ielantlsusncs Cad Peronalzston System Hardware Senice anual Page 144 5 Adjustments 3 If hopper transport was too far toward the front of the EC2000 increase the seting press the Bave button and go back to the beginning of this section 11 Press the Printer Ejec button 12 Remove the card from the image printer exit and recycle it 13 Re install hopper 2 and hopper 3 in the device 14 Press the Status button to retum to the Status page 5 3 How to Calibrate the XY Transport Module 53 1 About Callbrating the XY Transport There are two parameters that must be calibrated to make sure cards are properly handed off from the image printer to the XY transport Each setting represents the number of steps the XY motors should take to get to the specified location One setting tells the image printer how far to push cards out from its exit the X direction One setting tells the XY transport how far toward the front or rear of the device the Y direction it should park to take cards from the image printer The XY transport should be far enough forward that cards coming out of the image printer slide into its card clamp and push the spring loaded rail the justifier at the printer exit a short distance 0 04 to 0 06 toward the front of the device Thi
41. 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 ocket 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 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 poor performance and in some cases may be hazardous 20000 Wate Tsuen Cari Personalizar System Hardware Senice anual Page 3 0 Table of Contents Table of Contents Table of Contents 1 Required Tools Materials and Documents 11 12 13 14 15 2 Introduction 21 22 23 24 25 26 27 28 29 3 Preventive Maintenance 34 32 33 34 35 36 37 38 39 340 341 342 343 344 345 Required Tools Suggested Tools Required Materials Suggested Material Required Software and Documents Recommended Preparation for Service Appointments Important Safety Information How to Handle ESD Sensitive Parts Introduction to EC2000 Components Device
42. 0 and Figure 4 36 for reference Figure 4 36 3 of 4 Hopper Module Screws TOP RIGHT VIEW 13 Locate the hopper transport belt It will remain attached to the hopper transport during removal 14 Release the tension on the hopper transport belt by using the 5 32 Allen wrench to loosen the belt tension screw on the front of the hopper module see Figure 4 37 pret 2000 Tela Cad Personalizar System Hardware Senice anual Page 66 4 Removal and Re installation Figure 4 37 Hopper Transport Belt Tension Adjustment Screw FRONT RIGHT VIEW 15 Carefully slip the hopper transport belt off the gear of the motor mounted to the top deck plate near the rear of the hopper module see Figure 4 38 Figure 4 38 Hopper Transport Belt und Drive Motor FRONT RIGHT VIEW 16 Use both hands to carefully lit the hopper module out of the device making sure no cables are snagged on the hopper module or the device and set it aside pret 00D Ielantlausncs Cani PETRIE System Hardware Senice anual Page 67 4 Removal and Re installation To re install the hopper module follow these steps 1 Note that if any cables or cable ties are too difficult to reach during the following steps you can remove the hopper deck the steel plate on the top of the hopper module use the 5 64 Allen wrench to remove the five screws that secure it to the hopper module and set the screws and deck aside 2 On the
43. 121 or equiv ETT MSP ADHESIVE RTV SILICONE 90ML CLEAR If removing image printer touchscreen embedded PC or MSR 1 4 Suggested Materials Part Number Quantity Description 33011009 Tea ASM KIT STARTER SPARE FIELD 2000 93400047 Tea PRI RIBBON COLOR YMCKOK EV R3314 33070896 Tea RIBBON ASSY TIP FOIL SILVER 33070621 Tea _ASSY INDENT CARTRIDGE 1 5 Required Software and MagTek recommends loading the following required software and documents on the USB thumb drive or laptop before visiting the customer site Documents Part Number Quantity Description 99875600 Tea MNL USER INSTALL amp OPERATION MANUAL EC2000 99875607 Tea MNL HARDWARE SERVICE MANUAL EC2000 99875609 Tea MNL PARTS CATALOG EC2000 99875651 Tea REF PROCEDURE PREVENTIVE MAINTENANCE EC2000 99875646 Tea REF CHECKLIST PREVENTIVE MAINTENANCE EC2000 le EC2000 reference image CA from a working EC2000 loaded onto USB thumb drive or service laptop Tea Set of passwords for the device being serviced NA Tea Factory defaults for the device being serviced VARIOUS more EC2000 software patch files provided by MagTek Support Servic loaded onto USB thumb drive or service laptop pret 20000 Ielantlsusncs Cani PEATE System Hardware Senice anual Page 8 2 Introduction 2 Introduction This document prov
44. Approximate time to remove 5 minutes plus any sub procedures Approximate time to re install 5 minutes plus any sub procedures The exit transport module takes cards from the XY transport module after embossing and moves them either to the card rejection bin or to the tipper and exit ramp It includes an integrated MagnePrint reader which can optionally be used to read each issued card s magnetic stripe and produce a digital identifier or DI for later validation that the card is genuine and that its encoded data has not been altered The exit transport is attached to the center of the device s top deck plate 46500145 4X 48310000 4X 48190012 4X 133070690 igure 4 90 Exit Transport Module FRONT LEFT VIEW To remove the exit transport module follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Remove the tipper and exit ramp module For detailed steps see section 4 13 How to Remove Re install the Tipper and Exit Ramp Module 3 Locate the multi connector panel in the top deck plate to the left of the exit transport Egress GODS sant anc Cari Fersonaion System Radar Serves Maal Page 111 4 Removal and Re installation 4 Locate the exit transport module s connect
45. FRONT VIEW 17 Ifthe card doesn t fit all these conditions adjust the handoff location by following these steps Navigate to Menu gt Settings Edit Config to open the first Configuration Editing password page b Enter password and press the E button to open the second password page Enter password 7654321 open the page d Scroll down in the list of settings until you find the PrinterHandofTAdjustmentX setting Ifthe card did not push far enough toward the second clamp decrease the PrinterHandoffAdjustmentX setting by selecting the number in the list pressing the E button then entering the new number on the on screen keypad and pressing the E button f Ifthe card did not make contact with the plastic portion of the clamp or did not press on the justifier and raise it a little bit decrease the PrinterHandoffAdjustmentY setting by clicking the number in the list pressing the button then entering the new number on the on screen keypad and pressing the E button 2 Press the Bave button to save your changes B Repeat the steps in this section until the card clamps correctly when it exits the printer Keep the card in the XY Transport for the next section 5 3 3 How to Callbrate XY Transport to Exit Transport Handoff calibrate where the XY Transport goes to push a card into the exit rollers follow these steps D 4 5 6 7 8 Make sure you have moved a card to the XY Transp
46. Figure 4 75 Unfastening Embosser TOP VIEW FROM FRONT and TOP VIEW FROM REAR 12 Use both hands to lift the embosser and indenter modules out of the device making sure the embosser cable does not catch on anything on the way out Set the modules aside 000 Ielantlsusncs Cad Pernalzston System Hardware Senice anual Page 97 4 Removal and Re installation To re install the embosser module follow these steps 1 Use both hands to lower the replacement embosser and indenter modules already together into the device in the same position and orientation as the one you just removed Line up the four corner screw holes in the embosser with the four corresponding screw holes in the top deck plate 2 Make sure the two raised keys stamped into the top deck plate see Figure 4 76 are seated in the indentations in the base of the embosser Push the embosser forward backward left and right to make sure they are holding the embosser in place Figure 4 76 Embosser Base Keys In Top Deck Plate TOP RIGHT VIEW Use the 5 32 ball end Allen wrench to re fasten and tighten the four screws and washers that attach the comers of the embosser to the top deck plate GODS Haan issuance Cari System Radar Serves anual Page 98 4 Removal and Re installation 4 Line up the three screw holes in the indenter module with the three screw holes in the embosser module and the top deck plate U
47. How to Remove Re install the Embedded PC Solid State Drive SSD Approximate time to remove 5 minutes plus any sub procedures Approximate time to re install 5 minutes plus any sub procedures The embedded PC s solid state drive SSD contains its operating system and software It is mounted to the embedded PC in the rear right corner of the lower deck tub of the device To remove the embedded PC s SSD follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Perform the first few steps in section 4 15 How to Remove Re install the Embedded PC just to the point where the SSD is accessible see Figure 4 100 Figure 4 100 Embedded PC Solid State Drive TOP VIEW FROM RIGHT 3 Use the No 1 Philips screwdriver to remove the two screws securing the SSD Upon removing the second screw the edge of the SSD should pop up on its own See Figure 4 101 00D Ieantlsusncs Cad Personalzston System Wartware Senice anual Page 119 4 Removal and Re installation Figure 4 101 Solid S Drive Screws TOP VIEW FROM RIGHT 4 Remove the SSD from the embedded PC and set it aside Egress GODS Tan issuance Cari Fersonaion System Hardware Serves anual Page 120 4 Removal and Re installation
48. MAGTEK ExpressCard 2000 Instant Issuance Card Personalization System Hardware Service Manual AUT June 2014 Manual Part Number 99875607 4 01 REGISTERED TO ISO 9001 2008 13710 Apolo 1 Seal Beach 90740 1 Prone 562 S46 400 T Technica Suppor GBB 6248380 ww magik com Copyright 2006 2014 MagTek Inc Printed in the United States of America Information in this publication is subject to change without notice and may contain technical inaccuracies graphical discrepancies Changes or improvements made to this product will be updated in the next publication release No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of MagTek Inc MagTek is a registered trademark of MagTek Inc MagnePrint is a registered trademark of MagTek Inc Magensa is a trademark of MagTek Inc MagneSafe is a trademark of MagTek Inc ExpressCard 2000 is a trademark of MagTek Inc Microsoft and Windows are registered trademarks of Microsoft Corporation All other system names and product names are the property of their respective owners Table 0 1 Revisions Rev Number Date Notes 1 01 12 112013 Initial release derived from 99875357 6 01 33099078 201 99875617 1 01 MagTek Support Services vid
49. Personalizar System Hardware Senice anual Page 175 B Adjustments 5 JE the text is not centered as shown follow these steps to center it Navigate to Settings gt ripper b Ifthe text was too high inside the rectangle inerease the value steps of 10 work well to start with put the tipper foil spool assembly back in the EC2000 and repeat these steps from the beginning Ifthe text was too low inside the rectangle decrease the value steps of 10 work well to start with put the tipper foil spool assembly back in the EC2000 and repeat these steps from the beginning d Press the Bave button to save settings and press to close the confirmation popup window 5 8 3 Calibrate Tip Angle Pressure D 2 3 4 Create a tipped sample card from Menu gt Samples Examine the card s foil tipped characters Make sure the tipper is not overflashing foil is being put on the flat portion of the card and is not leaving embossed characters uncovered See Figure 5 11 You may also be able to gauge the tipper calibration by removing and examining the foil Figure 5 11 Tipper Overflashing Left and Inadequate Coverage Right Ifthe tipper is not calibrated correctly follow these steps 3 Navigate to Menu gt Bettings gt Tipper b Ifthe tipper is overflashing use the arrow buttons to decrease the Tipper Motor Angie setting subtract 10 If you reduce to the minimum value of 160 s
50. Philips screwdriver Egress GODS Wan ance Cari POTEET Sam Hardware Serves anual Page 55 4 Removal and Re installation Figure 4 20 One of Eight 5 rews On Sides of Cover TOP VIEW FROM FRONT Figure 4 21 Plastic Fastener Plates LEFT VIEW 14 Locate the two screws that secure the front of the cover next to the tipper Cad Personalizar System Hardware Senice anual Page 56 4 Removal and Re installation Figure 4 22 Cover Screws Next to Tipper REAR VIEW 15 Use the No 2 Philips screwdriver to remove the screws and set them aside 16 Pull the silver portion of the cover forward slightly to release it from the device 17 Carefully remove the cover by pulling it forward a few inches with both hands making sure there are no cables tangled with it then pull it toward the ceiling and set it aside Figure 4 23 Removing the Cover FRONT LEFT VIEW 18 Perform any additional replacement or maintenance steps prea 00D Ielantisusncs Cad PETRIE System Hardware Senice anual Page 57 4 Removal and Re installation re install the cover follow these steps Note Re installing the cover is an intricate detailed procedure that can affect the security and functionality of the device Perform each step carefully and methodically and make sure everything is in place before proceeding to the next step 1 Move any loose cables toward the center of th
51. 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 Hopper Empty Unblocked when there is no hopper installed in the specified hopper slot Hopper Empty Tipper Cam Blocked when the tipper heating element isin 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 20000 Tata Tsuen Cari POTATO System Hardware Senice anual Page 16 2 Introduction Figure 2 4 All EC2000 Sensors Shown In Red FRONT VIEW GODS san issuance Cari System Hardware Serves anual Page 17 2 Introduction 2 9 3 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 gt Settings gt Service gt then enter service passwords 567890 and to open the Embosser Utility page Embosser Utility StpsiDirecion
52. Ribbon Cable FRONT VIEW To remove the XY transport module s ribbon cable follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Open the top access door by following the steps in section 2 7 How to Open the Top Access Door 3 Move the XY transport to the front of the device to expose its cable and its connection to the circuit board breakout board on the base plate of the device see Figure 4 59 and section 2 8 How to Safely Move Transports By Hand prea 000 Wala Tae Cad Personalzston System Hardware Senice anual Page 82 4 Removal and Re installation Exposing Breakout Board TOP VIEW Figure 4 59 XY Transport at Front of D 4 On the rear side of the XY transport locate the two retaining clips that secure the ribbon cable to the transport Lift both clips firmly toward the ceiling to unlock and eject the cable from the circuit board then disconnect the ribbon cable See Figure 4 60 re 4 60 Unlocking XY Transport Ribbon Cable TOP VIEW FROM LEFT REAR LEFT VIEW 5 Open the clip that secures the ribbon cable to the top deck plate 0000 Teta aan Cani PEATE System Hardware Senice anual Page 83 4 Removal and Re installation 6 Disconnect ribbon c
53. Scroll down in the list and select the number below the BotCardTridgeHomeToIndent item Egress anc Cari SM Hardware Serves anual Page 165 5 Adjustments Configuration Editing a 3 CRT e Press the button to clear the current value Ifthe letters were too far to the rear of the EC2000 enter a larger number for BotCardTridgeHomeTolndent You probably only need to change by 1 5 steps Ifthe letters were too far to the front of the EC2000 enter a smaller number for BotCardTridgeHlomeTolndent You probably only need to change by 1 5 steps button to finish entering the new value i Press the Bava button to save your changes The system will report The modified configuration has been saved Press OK to close the popup window 7 Navigate to Menu gt Bettings Service gt Cmds to open the Eontroller Commands page 8 Under the Indenter Move button select Bot Cartridge Load in the dropdown list Controller Commands Se atte Welton aa TEM J oe sw ia TET mem heme J tewerns rm pem an To Roter 9 Press the jndenter Move button The device will move the indenter to the load position pret Cad Peronalzston System Hardware Senice anual Page 166 5 Adjustments Controller Commands MAGTEK mE p coi vasann Tweed Es Lo Sare Home _ VTaEn
54. Specifications About Installation amp Operation How to Open the Top Access Door How to Safely Move Transports By Hand How to Use Maintenance Functions On the Touchscreen Prepare the Device for Preventive Maintenance Clean the Card Path Clean All Transport Rollers Update the Softwar Update the Firmware Service the Hopper Module Service the XY Transport Module Service the Exit Transport Module Cool the Tipper Heater Power Down the Devic Clean Inside the Device Service the Image Printer Module Service the Embosser Module Service the Electronics Service the Cover Perform Final Tests 00D Ielantlsusnce Cad Personalzston System Hardware Senice anual Page 4 0 Table of Contents 4 Removal and Re installation 44 42 43 44 45 46 47 48 49 440 441 442 443 444 445 446 417 418 419 4 20 421 5 Adjustments 5 1 to Calibrate the Touchscreen 5 2 to Calibrate the Hopper Transport Module 5 3 to Calibrate the XY Transport Module 5 4 How to Calibrate the Embosser Module 5 5 to Calibrate the Indenter Module 56 to Calibrate the Image Printer Module 5 7 Howto Minimize Image Printer Margins 5 8 How to Calibrate the Tipper Module 6 Diagnosis 6 1 Known Symptoms and Possible Causes Appendix A Technical Support Appendix Glossary How to Prepare the Device for Removing Re installing Modules How to Rem
55. able from the breakout board on the top deck plate and set the cable aside 7 Mf there is adhesive on any of the connectors peel or gently scrape it off and discard it Egress issuance Cari Stem Hardware Servis anual Page 84 4 Removal and Re installation re install the XY transport ribbon cable follow these steps 1 Locate the end of the cable labeled TO J6 XY TRANSPORT BOARD and connect it to the breakout board on the top deck plate with the cable coming off the board toward the front of the device Press down to make sure the connection is solid Figure 4 61 Breakout Board Connection of XY Transport Ribbon Cable TOP VIEW FROM LEFT 2 Route the cable through the clip that secures it to the top deck plate close the until you feel it click in place see Figure 4 62 and press down Figure 4 62 Locking XY Transport Ribbon Cable In Place TOP VIEW FROM LEFT 3 Make sure the loose end of the cable says J2 X CLAMP BOARD and is oriented as shown in Figure 4 63 prea 20000 TT Cani Personalzston System Hardware Senice anual Page 85 4 Removal and Re installation Figure 4 63 XY Transport End of Ribbon Cable TOP VIEW FROM LEFT 4 Connect the cable to the XY transport as shown in Figure 4 64 It should come off the XY transport toward the front of the device before looping back toward the breakout board 5 Push the retaining cli
56. ace the XY transport onto the top deck with the ground cable pointing toward the rear of the device lining up the holes in the XY transport module with the corresponding holes in the top deck plat 2 Inspect around and underneath the XY transport to make sure it isn t pressing any cables against the top deck plate or other modules 3 Make sure the four keys at the comers of the XY transport are seated in the corresponding slots in the top deck plate see Figure 4 69 Push the base of the XY transport forward and backward left and right to make sure they prevent it from moving around Figure 4 69 Transport Base Keys and Top Deck Plate Holes TOP RIGHT VIEW 4 Move the XY transport carriage toward the rear of the device see section 2 8 How to Safely Move Transports By Hand 5 Use the 1 8 Allen wrench to fasten and tighten the three screws securing the XY transport to the top deck plate near the front of the device see Figure 4 65 6 Move the XY transport carriage toward the front of the device see section 2 8 How to Safely Move Transports By Hand 7 Use the 1 8 Allen wrench to fasten and tighten the three screws securing the XY transport to the top deck plate near the rear of the device see Figure 4 65 S Re connect the Y stepper connection cable see Figure 4 68 9 Re connect the XY transport ribbon cable with the cable coming off toward the front of the device as shown in Figure 4 67 10 Hold the ri
57. 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 pase 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 change each tine s settings individually The page also provides Reset button that will reset all tine settings to factory defaults preva 2000 Ielantlsusncs Cani Personalizar System Hardware Senice Manaa Page 19 2 Introduction Emboss Settings MAGTEK Corent Sings h Device e o moo dw eG m e e Hold Char 348 01 008 32 a Tief Char FontiD Height 02 49 01 005 0 n 5 a2 03 50 01 005 16 04 51 01 005 10 Rec setra 05 52 01 005 0 fe alata Ie piam ee otcwentsotings setngs Pesetchar height 11 48 02 005 37 Wonders in values 12 49 02 005 10 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 gt Settings gt Service gt Embosser and enter service passwords 567890 and D987854 to open the Embosser Utility page then press the Bttings button below Ber Emboss Hold
58. and Figure 4 19 to constrain the cover from moving front to rear 15 Fully insert the eight screws that fasten the cover to the base Follow these helpful hints a Puta light below the screw holes before attempting to line them up b Use your free hand to push the cover into the right position to insert the screws c lt may be helpful to use the magnetic retriever tool to insert them into the holes then use the screwdriver or a finger to push them all the way in 16 One by one line up each of the plastic fastener plates below their matching screws hold them in place and tighten the screws The diagonal portion of each fastener plate will be in the midline of the device as shown Follow these helpful hints 3 The easiest tool to tighten the front comer screws is screwdriver with a heavy duty flex extension If one is not available they may be easier to tighten using the No 1 screwdriver leaned flush against the inside corner of the cover s top opening b For each plate fasten the midline screw first then the corner screw c Look into the cover from above to put the screwdriver firmly into the screw head first then crouch next to the device to line up the plate then tighten the screw partway d Do not push the plates too hard toward the ceiling or you may pop the screw out of its hole e Screw both screws partway into the plate before tightening them all the way Figure 4 29 Front Left Fastener Plate LEFT VIEW 17 T
59. and Operation Manual pret 20000 Ielantisusncs Cani Personalizar System Hardware Senice anual Page 10 2 Introduction 2 6 About Installation amp Operation For detailed instructions about planning installation operation and basic maintenance see 99875600 EC2000 User Installation and Operation Manual 2 7 Howto 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 MICE 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 prevent injury or damage to the device follow these guidelines Ifyou 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 Ifa card is stuck in the hopper t
60. ape to the hopper transport s motor as shown 9 Make sure the hopper transport belt is looped around the drive gear at the front of the hopper transport module as shown 10 Route the EXC HOME SENS cable from the front of the hopper module to the right of the device around the hopper mounting legs then toward the rear of the device as shown in Figure 4 4 pret 2000 ETE TRU Cad PETITES System Hardware Senice anual Page 69 4 Removal and Re installation 11 Loop a cable tie through the anchor point on the top deck plate near the front of the device tie the EXC HOME SENS cable to the other cables and tighten and trim the cable tie see Figure 4 41 Figure 4 41 EXC HOME SENS Cable Routing TOP LEFT VIEW 12 Continue routing the EXC HOME SENS cable along the right side of the device and thread it under the right side of the HOPPER SHUTTLE board then out the front as shown in Figure 4 42 Figure 4 42 Routing the EXC HOME SENSOR Cable FRONT VIEW 13 Use a miniature cable tie to fasten the EXC HOME SENS cable near the front of the device securing it to the bundle of cables that runs along the right side of the device see Figure 4 43 prea 00D Ielantlsusmcs Cad Personalizar System Hardware Senice anual Page 70 4 Removal and Re installation Figure 4 43 Securing the EXC HOME SENS Cable TOP VIEW FROM FRONT 14 Use a miniature cable tie to fasten the EXC HOME SENS cable to the sam
61. ase Open sensor cable in the rear left corner of the device pret 0000 Ielantlssusncs Cani Personalizar System Hardware Senice anual Page 53 4 Removal and Re installation 11 Disconnect the Door 2 Solenoid cable connected to the top access door latch on the left side of the device Disengage the bottom part ofthe cable from the clip on the wall of the cover Figure 4 17 Door 2 Solenoid Cable RIGHT VIEW 13 Use the No 2 Philips screwdriver to remove the fastener that secures the cover to the metal plate on the rear face of the base It can be found in the upper rear right of the device behind hopper 1 as shown in Figure 4 17 2000 WT Tae Cari Perenalzston System Hardware Senice anual Page 54 4 Removal and Re installation Figure 4 18 Removing the Right Side Cover Screw Near Top Access Door Hinge FRONT LEFT VIEW 14 Use the No 2 Philips screwdriver to remove the screw and washer in the rear upper left of the device opposite the fastener you have already removed see Figure 4 20 Figure 4 19 Removing the Left Side Cover Screw Near Top Access Door Hinge FRONT RIGHT VIEW 12 Locate the eight screws and washers and four plastic plates that clamp the two sides of the cover to the top deck plate see Figure 4 9 13 Use the No 2 Philips screwdriver to remove the screws washers and plates and set them aside Note The front two screws may be easier to remove with the No 1
62. at will reduce the risk of breaking the touchscreen s adhesive during other service 2 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 3 Remove the cover by following the steps in section 4 4 How to Remove Re install the Cover 4 Place the cover on a protected surface with the touchscreen toward the floor Egress GODS san issuance Cari Fersonaison System Radar Serves anual Page 138 4 Removal and Re installation 5 Remove the four screws that secure the touchscreen retaining plate to the cover see Figure 4 126 and set them aside Figure 4 126 Touchscreen Retaining Plate Screws REAR VIEW 6 Remove the touchscreen retaining plate and set it aside 7 Remove the touchscreen and set it aside TERRES 200O REET ance Cari Stam Hardware Serves Mana Page 139 4 Removal and Re installation To re install the touchscreen follow these steps 1 Place the cover on a protected surface with the front touchscreen opening toward the floor 2 Put the touchscreen in place 3 Put the touchscreen retaining plate over the touchscreen so the screw holes line up with the screw holes in the cover 4 Use the No 2 Philips screwdriver to insert and tighten the screws 5 Perform any other service that requires the cove
63. ave button 3 Repeat the process until the embossed character lines up with the printed one pret 00D Cad PETRIE System Hardware Senice anual Page 159 5 Adjustments Look at the FIRST letter at the bottom of the card Adjust Card X Offset Card Y Offset 1 Card X Offset Card Y Offset Card X Offset 1 Card Y Offset y Card Y Offset 1 Card X Offset Finished Card X Offset 1 Card X Offset Gara X Oft 7 Card Y Offset 1 Card Y Offset 1 Guay Ode 7 Calibrate the X SPFand Y SPI settings which changes the spacing oF all Tonis a Press the Prini button The EC2000 will create test card with all font IDs b Look only at the last character of the long string of letters at the bottom of the card Font ID2 from all angles and determine whether the embossed character is to the left right above or below the printed character c Press the Advanced button to open the Tuning Advanced page Egress 2000 Tan ance Cari Fersonaison Sam Hardware Serves anual Page 160 5 Adjustments Tuning Advanced Y Steps Inch Adis Oi Da Fomin Forio ma Fontis S Steps Per nch Adjust AUN Stetching Leto iat E IE the embossed character appears to the left of the printed character increase the X SPI value and press the large button If the embossed character appears
64. bbon cable in place in the middle of the clamp Being careful not to pinch the cable close the clamp and press until you feel it lock closed 11 Use the No 2 Philips screwdriver and optionally the hemostat pliers to reattach the XY transport ground cable to the top deck plate behind the image printer 12 Re attach the top access door by reversing the steps you used to lean it back 13 Calibrate the XY transport using the information in section 5 3 How to Calibrate the XY Transport 14 From the touchscreen navigate to MERU gt create sample card and make sure the device functions properly and the sample looks correct Egret 200O stant vance Cari System Serves anual Page 91 4 Removal and Re installation 15 If the EC2000 does not power up or function properly contact MagTek Support Services for assistance see Appendix A Technical Support preter 20000 Wate Tsuen Cari Personalizar System Hardware Senice anual Page 92 4 Removal and Re installation 4 10 How to Remove Re install Embosser Fonts Under normal circumstances the characters on the embosser module s daisy wheel do not need to be removed Embosser characters should be removed and replaced as little as possible because removal causes the tine to wear and eventually become less effective at holding characters If a tine breaks however it may be necessary to move its character to a new tine Figure 4 70 Rem
65. betser _ Embere rot J 1 Raa connie Nassau _ Emboss P04 _ Shine Te Pinter Can aa To itr _ Cong Cw sess Home aes 10 Repeat the steps in this section until the negative letters or numbers on the rear indent cartridge are centered between the top and bottom edge 5 5 3 How to Calibrate the Front Indent Cartridge Positions If the device you are calibrating has a front indent ribbon cartridge which has white ribbon and mounts above the embosser follow the steps from section 5 5 2 How to Calibrate the Rear Indent Cartridge Positions with the following modifications Everywhere the steps specify Bottom or Bot read as Top Everywhere the steps specify Rear read as Front 5 6 Howto Calibrate the Image Printer Module These steps may be necessary after installing a new image printer or after installing software firmware driver updates 5 6 1 About Callbrating the Image Printer The EC2000 provides options to configure the image printer Settings include how it prints whether it includes lamination Overlay on each side of the card the stretching and position of images the fonts it uses to print each embossed Font ID and so on 5 6 2 How to Set Ribbon Driver Settings Card Exit Distance set the image printer to factory settings follow these step
66. characters into the card at the same location where those characters have been inked Clearly in this type of process it is important for both steps of the process to print and stamp the characters precisely on top of each other Occasionally after periodic maintenance or firmware updates embossed and printed characters may become misaligned Re aligning them is called Tuning and it involves adjusting both character position and the character spacing Figure 5 8 shows what a card may look like if the position is not properly tuned Figure 5 8 Embosser Not Properly Tuned Custom applications may use the fonts in different ways but the most typical arrangement is shown in Figure 5 9 The list of available fonts and their typical uses is in Table 5 1 TERRES GODS san ance System Hardware Serves anual Page 157 5 Adjustments Font ID1 Font ID2 nt 103 Figure 5 9 Fonts and Corresponding Font IDs Table 5 1 Fond ID Fields FIELD ID DESCRIPTION Font IDI Generally used for the Primary Account Number PAN the account number either a debit or a credit card Font ID2 Generally used for the cardholder name and the card expiration date Font ID3 Reserved for devices equipped with Visa Electron or American Express fonts Font 04 The rear indent font generally used for the CVV code on the back side of the card next to the magstripe 8 2 How to Allgn
67. ckle is pressing too hard or the bottom knuckle isn t pressing hard enough or both Follow these steps to adjust one of them a If most of the embossed character heights are greater than 0 0180 decrease the pressure on the top knuckle by subtracting 1 from the current setting see Figure 5 3 b HE most of the embossed character heights are less than 0 0180 increase the pressure on the bottom knuckle by adding 1 to the current setting see Figure 5 3 c Create and measure a tuning card and repeat the steps in this section until the card is flat or slightly frowning and the embossed character thickness is between 0 0170 in and 0 0190 in 4 Ifthe card is concave down frowning when face up either the top knuckle is not pressing hard enough or the bottom knuckle is pressing too hard Follow these steps to adjust one of them 3 If most of the embossed character heights are less than 0 0180 increase the pressure on the top knuckle by adding 1 to the current setting see Figure 5 3 b HE most of the embossed character heights are greater than 0 0180 decrease the pressure on the bottom knuckle by subtracting 1 from the current setting see Figure 5 3 c Create and measure a tuning card and repeat the steps in this section until the card is flat and the embossed character thickness is between 0 0170 in and 0 0190 in or until a single knuckle setting change has changed the card from slightly concave up to slightly concave down 5 4 7 How
68. ct USB Cable to J31 TOP VIEW FROM REAR 6 Secure the power cable to its connector using a bead of silicone adhesive as shown in Figure 4 57 Figure 4 57 Silicone Adhesive On Image Printer Power Connector FRONT RIGHT VIEW 7 Re attach the top access door by reversing the steps you used to lean it back 8 Install the original printer ribbon or obtain and install new image printer ribbon from the customer 9 Re connect the power and network cables to the device and power it up 10 Configure the image printer ribbon following the steps provided in 99875600 ExpressCard 2000 User Installation and Operation Manual 11 Perform any relevant adjustments from section 5 Adjustments notably sec Calibrate the Image Printer n 5 6 How to 12 Close and secure the top access door 13 From the touchscreen navigate to Mem gt create sample card and make sure the device functions properly and the sample looks correct prea 00D Ielantlsusmcs Cad Personalzston System Hardware Senice anual Page 81 4 Removal and Re installation 4 8 How to Remove Re install the XY Transport Ribbon Cable This section provides information for replacing just the XY transport ribbon cable which occasionally must be replaced without replacing the entire module For instructions on removing and re entire XY transport module see section 4 9 How to Remove Re install the XY Transport Figure 4 58 XY Transport Showing
69. d 4 Use the long No 2 Philips screwdriver to tighten the rear thumb screw 5 Use the long No 2 Philips screwdriver to tighten the front thumb screw 6 Tug on the side 7 Remove any props under the device s feet and retum it to its original location ss door to make sure it is secure prea 0 Personalizar System Hardware Senice anual Page 49 4 Removal and Re installation 4 4 Howto Remove Re install the Cover Approximate time to remove 30 minutes plus any sub procedures Approximate time to re install 45 minutes plus any sub procedures The EC2000 has a cover which secures the device s contents and provides mount points for the top access door and touchscreen and incorporates the card output hopper and manual feed slot Some service procedures require removing the device s cover to give unobstructed access to certain components Figure 4 9 Cover REAR LEFT VIEW REAR RIGHT VIEW Follow these steps to remove the cover 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Remove the top access door by following the steps in section 4 2 How to Remove Re install the Top Access Door including safely powering down and disconnecting external cables 3 Remove the magnetic strip
70. d and to make sure the card is being squeezed evenly on both sides see Figure 5 2 pret 00D Ielantlsusncs Personalizar System Hardware Senice anual Page 147 5 Adjustments Figure 5 2 Embosser Knuckles REAR LEFT VIEW and PROFILE VIEW Each knuckle can be rotated to point one of its six faces toward the card being embossed Each face presses to a different depth 43 is the highest pressure setting and 3 is the lowest pressure setting You can read the current depth by looking at the shape carved into the side of the knuckle that faces the card see Figure 5 3 Deepest lightest Impression Impression Figure 5 3 Embosser Knuckle Heights Key 43 Most Pressure 3 Least Pressure Embossers should have ink marks indicating factory calibrated positions for the top and bottom knuckle as shown in Figure 5 4 Figure 5 4 Marking Factory Default Knuckle Position REAR VIEW Cani Personalizar System Hardware Senice anual Page 148 5 Adjustments The embosser can also be calibrated using settings in the software A label on the base of the embosser should show the factory default settings for the embosser knuckles and for the CamAngle settings as shown in Figure 5 5 Figure 5 5 Factory Default Knuckle and CamAngle Settings TOP VIEW FROM FRONT Many of the following sections require you to create a tuning card then measure the thick
71. d PEATE System Hardware Senice anual Page 20 2 Introduction 2 9 4 Howto Use the Character Mapping Page The Eharacter Mapping page provides support for changing the configuration of characters on the C2000 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 different tine and removing a character from 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 gt Bettings Bervice 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 Ifthe 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 Install both halves of the character on the new tine 4 From the touchscreen navigate to Menu gt Bettings gt Char
72. d 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 2000 ETE TESTE Cari Personalna System Hardware Senice anual Page 21 2 Introduction 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 FontlD2 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 blank flat side that goes opposite the punch side 2 Install both halves of the character on the new tine 5 From the touchscreen navigate to Menu gt Bettings Bervice Char Map to open the first Eharacter Mapping password page 6 Enter password then press the E key to open the second Tharacter Mapping password page 0987654 then press the E key to open the Character Mapping paze 7 Enter passwor Use the Add Char dropdown list to select what character you are installing for example if you are installing a capital A sel
73. e bundle of cables near the flex cable as shown 15 Locate the HOME SENS cable that comes from the rear of the hopper module Route it along the rear wall of the device to the left side of the hopper module and below the shielding around the image printer as shown in Figure 4 44 If there is not enough slack in the cable use the 5 32 Allen wrench to seat the cable below the axle of the hopper motor s gear as shown in Figure 4 45 Egress GODS Wan ace Cari Fersonalion Stem Radar Serves anual Page 71 4 Removal and Re installation Figure 4 44 Figure 4 45 Optional Routing for TOP VIEW FROM FRONT RIGHT 16 Continue routing the HOME SENS cable along the bundle of cables that runs below the left edge of the hopper module Use cable ties to re bundle the cables as shown in Figure 4 46 00D Ielantlsusncs Personalizar System Hardware Senice anual Page 72 4 Removal and Re installation Figure 4 46 Routing the HOME SENS Cable TOP FRONT VIEW 17 Continue routing the HOME SENS cable under the clip just to the left of the HOPPER SHUTTLE circuit board as shown in Figure 4 47 Figure 4 47 Routing the HOME SENS Cable FRONT VIEW 18 Plug the two sensor cables into the HOPPER SHUTTLE circuit board see Figure 4 48 3 The HOME SENS cable from the rear of the hopper module plugs into the left connector labeled HOME SENS b The EXC HOME SENS cable from the front
74. e device so they will not be in the way of the cover 2 Stand in front of the device and use both hands to slide the cover forward until it rests solidly on the base of the device and does not have to be held in place Figure 4 24 Cover Resting On Top Deck REAR VIEW 3 Move the cover slightly to the right and rest its right side on the tabletop next to the devi give you easier access to the connectors around the hopper module this will 4 Re connect the cables you disconnected before removing the cover 5 Re tie or re clip any cables you untied or unclipped before removing the cover 2000 Ielantlauance Can Personalna System Hardware Senice anual Page 58 4 Removal and Re installation 6 Apply silicone adhesive to secure the touchscreen power and video cables as shown in Figure 4 25 Figure 4 25 Silicone Adhesive On Touchscreen Connectors REAR VIEW 7 Bring the cover back up to resting squarely on the base as shown in Figure 4 24 Stand in front of the device and look straight down over the front Locate the extension of the cover s card output hopper that will meet up with the end of the exit ramp see Figure 4 26 Push that portion of the cover gently toward the floor and slide it slightly toward the rear of the device just until the base of the device captures it Figure 4 26 Card Output Hopper Touching Device s Base REAR RIGHT VIEW 9 Crouch in front of the device P
75. e installation Figure 4 112 Power Controller LEFT V W 12 Unscrew the thumb screws on the front and rear of the power controller to disengage it from the bottom deck The screws are part of the power controller tray and should spring up when they are disengaged Do not attempt to remove them from the tray 13 Lift the cables that run across the edge of the power controller tray to the power supply and use the finger holes to pull the power controller out a few inches to expose the three connectors near the front of the printed circuit board as shown in Figure 4 113 14 Disconnect the cables from the three connectors and move them out of the way toward the outsides of the left side access door Teasa 20000 TT TRU Cani Personalizar System Hardware Senice anual Page 128 4 Removal and Re installation Figure 4 113 Disconnect Three Cables rom Power Controller LEFT VIEW 15 Use the finger holes to continue carefully pulling the tray out of the device Make sure it does not snag on any cables or other parts Remove it from the device and set it aside in a static safe location pear 00D Ielantlsusmcs Cad Peronalzston System Hardware Senice anual Page 129 4 Removal and Re installation To re install the power controller and backplane reverse the steps you followed to remove it Follow these hints to make the re installation easier Before inserting the tray re route the two cables t
76. e left side access door by following the steps in section 4 3 How to Remove Re install the Side Access Doors 3 Take appropriate steps to protect the work surface the EC2000 is on paying special attention to the area where the security ring will make contact with the surface in the following step 4 With a partner safely and carefully tip the EC2000 onto its rear side to give you access to the bottom of the device as shown in Figure 4 117 Figure 4 117 Device Tipped With Rear Side Down FRONT VIEW 2000 Ielantlasuance Cari Personalnton System Hardware Senice Manual Page 131 4 Removal and Re installation 5 Locate the power supply in the rear of the device behind the left side access door Figure 4 118 Power Supply LEFT SIDE VIEW 6 Remove the clear plastic cover that protects the power supply inputs 7 Use the No 2 Philips screwdriver to loosen the screws that secure the three power input wires to the power supply then disconnect the wires 20000 Tela Tae Cari Personalizar System Hardware Senice anual Page 132 4 Removal and Re installation Figure 4 119 Power Supply Input Wires LEFT VIEW 8 Unplug the white plastic power supply control and monitoring connector shown in Figure 4 120 Figure 4 120 Power Supply Control and Monitoring Connector LEFT VIEW 9 Use the No 2 Philips screwdriver to loosen the screws holding the power supply output cab
77. e of the top knuckle by adding 1 to the current setting see Figure 5 3 b Ifthe card is bent concave up smiling increase the pressure of the bottom knuckle by adding 1 tothe current setting see Figure 5 3 c Repeat all steps in section 5 45 5 Ifthe highest FontIDI thickness you measured is higher than 0 0190 in a Ifthe card is bent concave up smiling decrease the pressure of the top knuckle by subtracting 1 from the curent setting see Figure 5 3 b Ifthe card is bent concave down frowning decrease the pressure of the bottom knuckle by subtracting 1 from the curent setting see Figure 5 3 e Repeat steps in section 5 45 6 Repeat section 54 5 for FontID2 5 4 6 How to Calibrate Card Flatness TOP EMBOSSING FORCE IS TOO GREAT ee GOOD CARD REFERENCE LINE a GOOD CARD REFERENCE LINE BOTTOM EMBOSSING FORCE IS TOO GREAT Egress 2000 Wan ance Card Fersonalion Sam Radar Serves anual Page 154 5 Adjustments After calibrating thickness there still may be some bending in the card Eliminate bending as much as possible by following these steps 1 Place the latest tuning card on a flat table and look at it from the side very small amount of concave down bend frowning is acceptable bending upward smiling is not acceptable 2 Flip the card over and make sure the other side is also flat 3 Ifthe card is concave up smiling either the top knu
78. e reader by following the steps in section 4 20 How to Remove Re install the Magnetic Stripe Reader MSR Module 4 Remove all the card stock hoppers from the device and set them aside Remember to move the hopper transport out of the way as you remove them see section 2 8 How to Safely Move Transports By Hand for more information Egress GODS Tan ac Card Sm Radar Serves Mana Page 50 4 Removal and Re installation 5 Disconnect the BEZEL LED signal cable from the inside of the manual feed slot Figure 4 11 Bezel LED Signal Cable REAR VIEW 6 Disconnect the Exception Card Entry sensor cable in the front right corner of the device ET 20000 Tata Cani Personalzston System Hardware Senice anual Page 51 4 Removal and Re installation Figure 4 13 Door 1 Sensor Cable REAR VIEW 8 Disconnect the touchscreen VGA video cable and the power cable from the rear of the touchscreen If there is any silicone adhesive on the cables or their connections remove it completely Cani Personalizar System Hardware Senice anual Page 52 4 Removal and Re installation 9 IE there are any cable ties anchoring the touchscreen cables to the cover use the wire cutters or diagonal cutters to cut the cable ties and replace them when re installing the cover Figure 4 15 Touchscreen Power and VGA Cables REAR VIEW 10 Disconnect the Top C
79. e the daisy wheel has a character positioned between the embosser hammers If the daisy wheel is off center 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 checkbox Note This feature only locks out movement when pressing the Close Clamp button and will not prevent lamp 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 Clamp Motor Move or Bottom Clamp Move button OR press the fase Clamp bution OR press the Motors Stop bution if you find you have moved too far and need to release the cams immediately 8 Repeal the moves as necessary to complete the test 9 Press the 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 Btatus page 2 9 3 4 How to Change the Embosser Character Depth and Dwell Time Over time or after embosser service
80. e 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 4 78 you may be working an older device contact MagTek for alternate instructions Cari Fersonalion Sam Hardware Serves anual Page 101 4 Removal and Re installation Figure 4 78 Tipper Heater Cable Tie TOP LEFT VIEW 6 Unplug the tipper heater cable Figure 4 79 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 Egress GODS Wan issuance Cari Fersonalion System Hardware Serves anual Page 102 4 Removal and Re installation Figure 4 80 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 Figure 4 81 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 Egress GODS san ance Cari SM Hardware Serves MART Page 103 4 Removal and Re installation Figure 4 82 Supporting the Tipper Heater While Removing Tightening RIGHT VIEW 10 Slide the tipper heater
81. ea TOOL KIT FIELD SERVICE EC2000 67800019 or equiv 1 ea Small USB keyboard with touchpad mouse NA m Small diagonal side cutters Tea X Acto knife if removing embosser characters NA Tea Micrometer or digital calipers if calibrating embosser NA Tea ESD grounding wrist strap NA Tea ESD mat and or ESD bags NA Tea USB thumb drive with required software and documentation Tea Thin tipped permanent marker 12 Suggested Tools Part Number Quantity Description Tea Laptop with available Ethernet port 22350302 or equiv 1 ea 10 ft Ethernet cable COM ETHERNET CATSE BLK 10 NA Tea Pen or pencil NIA Tea Paper and clipboard NA Tea Flashlight NA Tea Needle nose pliers NA Tea Hemostat pliers NIA Tea Slotted screwdriver NA Tea Cable tie tool with adjustable tension Tea Multimeter NA Tea Flex Phillips screwdriver OR Electric screwdriver with flex extension 1 3 Required Materials Part Number Quantity Description 97200153 Tea ASM KIT PREVENTIVE MAINTENANCE EC2000 NIA Tea Any replacement kits specified in the work order Fora list of kits see 33011011 REF LIST REPLACEMENT KITS EC2000 NA Fea Cloth clean and lint free pret 20000 Ielantlsusnce Cari Personalizar System Hardware Senice anual Page 7 1 Required Tools Materials and Documents Part Number Quantity Description 97200
82. ect 65 Verify you have selected the character you expected to select by looking at the ASCH Char box next to the dropdown list 9 Use the Fant dropdown list to indicate the type of font you have installed FontID1 4 10 Use the Fo dropdown list to select which tine you have installed the characters on 11 Press the dl button 12 Repeat the above steps for any additional characters you need to add 13 Test your changes by creating sample card or an embosser tuning card pret 00D TTA Cad PESTER System Hardware Senice anual Page 22 3 Preventive Maintenance 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 Egress GODS issuance Cari Serves anual Page 23 3 Preventive Maintenance nam Remove serative Deve poweradu
83. een the rails as shown in Figure 4 67 Figure 4 67 XY Transport Ribbon Cable TOP VIEW FROM FRONT 7 Grasping the XY transport ribbon cable by the connector not the cable itself disconnect it from the top deck 8 Locate the connectors in the middle of the Y stepper connection cable which runs along the left rail of the XY transport see Figure 4 68 9 Hold the two connectors not the wires and disconnect them 20000 Ielantisusncs Cari Peronalzston System Hardware Senice anual Page 89 4 Removal and Re installation igure 4 68 XY Transport Y Stepper Connection Cable TOP VIEW FROM LEFT 10 Use the 1 8 Allen wrench to remove the three screws securing the XY transport to the top deck plate near the rear of the device see Figure 4 65 and set them aside 11 Move the XY transport toward the rear of the device see section 2 8 How to Safely Move Transports By Hand 12 Use the 1 8 Allen wrench to remove the three screws securing the XY transport to the top deck plate near the front of the device see Figure 4 65 and set them aside 13 Use both hands on the rails to carefully lift the XY transport module of the device making sure no cables catch on any other modules and set it aside EET 20000 Ielantlsusncs Cae Personalzston System Hardware Senice anual Page 90 4 Removal and Re installation re install the XY transport module follow these steps 1 Pl
84. eir pins or circuitry GODS san ance Cari Fersonaion Stem Hardware Serves anual Page 9 2 Introduction 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 99875400 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 VIEN LEFT Figure 2 1 FrontRear LefURight 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
85. eos 201 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 cross references Improve cover removal e 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 301 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 401 06 21 2014 Update troubleshooting information about uneven tipping general updates to tipper heater replacement preter 20000 Westen Tsuen Cari Personalizar System Hardware anual Page2 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 Cla
86. ers 7 a couple measurements of different characters in the same font set and note the highest and lowest values for each font 5 4 4 How to Pre Set Embosser Defaults The embosser is designed to turn its cam by at least a certain angle to work properly In cases where you do not already have a starting point to calibrate the embosser set the embosser to its minimum CamAngle setting for all fonts and to light knuckle settings by doing the following 1 Open the top access door GODS Tan ance Cari Stam Hardware Serves anual Page 151 5 Adjustments 2 Check to see if the embosser has a yellow mark across its knuckles and rocker arm If it has been marked set the knuckles to those settings Otherwise set the knuckles to light defaults 3 Set the bottom surface of the top knuckle to 2 It may be helpful to turn the knuckle 3 clicks to read the setting then turn it back b Set the top surface of the bottom knuckle to 1 It may be helpful to tur the knuckle 1 click to read the setting then turn it back 3 Check to see if the embosser has a sticker on its base saying what top and bottom embosser cam angle settings to use as defaults If it has a sticker use those settings in the following steps otherwise set the top and bottom embosser cam angle for Font IDI 2 and 4 to 160 and FontlD3 to 110 as follows 3 Inthe ExpressCard Utility navigate to Menu gt Settings gt Edit
87. ersonalizar System Hardware Senice anual Page 123 4 Removal and Re installation To re install the MLB reverse the steps you followed to remove it When you insert it into the device make sure to line up the MLB tray with its tracks on the lower deck see Figure 4 99 Push it gently into the slot until you feel a small amount of friction When the thumb screws can be tightened without popping back up it is lined up properly Figure 4 106 Tracks for Embedded PC and Main Logic Board RIGHT VIEW After re installing the MLB follow these steps 1 Depending on the situation it may be necessary to complete additional software or hardware configuration steps as directed by your reseller MagTek Support Services or MagTek Engineering BEFORE powering up the device 2 Perform any additional service that requires the device to be powered off and open 3 Close the top access door 4 Re attach the power cable network cable and any security hardware 5 Power up the device 6 From the touchscreen navigate to Menu create sample card and make sure the device functions properly and the sample looks correct 0000 Ielantlsusnce Cari Pernalzston System Hardware Senice anual Page 124 4 Removal and Re installation 4 18 How to Remove Re install the Power Controller and Backplane Approximate time to remove 30 minutes plus any sub procedures Approximate time to re install 30 minutes plus an
88. es plus any sub procedures Approximate time to re install 30 minutes plus any sub procedures The heater in the tipper module fuses the tipper foil to the embossed characters on cards It is a replaceable part that wears out over time and must be replaced approximately every 12 000 cards 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 4 1 How to Prepare the Device for Removing Re installing Modules 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 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 Figure 4 77 Tipper Heater Cable TOP VIEW FROM FRONT 5 Cut the plastic cabl
89. f 4 wires power proud des tu and dat out preva 20000 Ielantlsusncs Cani PEATE System Hardware Senice anual Page 179 Appendix C Key Loading Used Cards A card that possesses all the components required for its intended purpose which has not been subjected to any personalization or testing operations and which has been stored in a clean environment with no more than 48 hours exposure to daylight at temperatures between 5 C and 30 C and humidity between 10 and 90 without experiencing thermal shock XML Extensible markup language XY Transport Assembly that travels in the X axis and Y axis YMCKO The designation of colored ribbon by the panels of color in the order in which they are applied Yellow Y Magenta Cyan Black and Overlay YMCKOK The designation of colored Ribbon by the panels of color in the order in which they are applied Yellow Y Magenta Cyan C Black K Overlay O Black K used for backside black only printing ZCMK Zone Control Master Key Appendix C Key Loading For information about loading keys for smart c Contactless Cards see 99875603 EC2000 How to Inject Keys for pred 0000 Teta Cani Personalizar System Hardware Senice anual Page 180
90. f the device do not sit because calibration depends on your viewing angle and most of our users will be standing in front of the device on a countertop 3 From the touchscreen s Windows desktop open the Tools shortcut 4 From the Tools folder launch the Fouchkit shortcut to open the Fouchki window 5 Select the oos tab USB Coniroller 088 SEET imas Depart aigrmentto matsh Taitraion Clea ard Clar inoaizaton parameter and do 4 porte Calats sigment Do 9 pirt inearzation for better touchsceen Lrearation ray Tex Do ten testo veil he touch accuscy 6 Press the button pred 00D Weta Cani Personalizar System Hardware Senice anual Page 141 5 Adjustments ting Took Edge Hach Aboa Linaaizaten Cuve i Panis to match ply Dea noaizaton parameter and do points Colas 3ignment Do 3 parts ineaizaten ler bete touchecreen meas Do chav testo very the touch acce Draw Test d d Cancel 7 Press and hold the center of the X on the screen until it stops flashing and turns solid blue 8 Repeat for all Xes that appear on the screen until the system reports 4 points calibration completed Press Ok to continue 9 Press the DK button to dismiss the popup window
91. g all other service service the cover as follows 1 Inspect the cover for damage 2 Clean the black and gray portions of the outside of the cover with alcohol wipes Clean fingerprints off the touchscreen with a soft clean dry cloth 3 15 Perform Final Tests After completing preventive maintenance follow these steps to test the device and restore it to its original state 1 Re connect the power and network cables 2 Re attach any security hardware 3 Re install consumables 4 Close all open doors 5 Power up the device 6 Re synchronize the image printer ribbon 7 Create a sample card using customer card stock 8 Check image print quality and embosser alignment and adjust components as necessary using the information in section 5 Adjustments 9 Fill out the checklist included with the preventive maintenance kit and return it to MagTek Egress GODS Want issuance Cari Fersonaison System Radar Serves anual Page 42 4 Removal and Re installation 4 Removal and Re installation This section describes how to remove and re install the major assemblies within the EC2000 avoid personal injury or damage to the device be sure to follow ESD procedures see section 2 3 How to Handle ESD Sensitive Parts and use standard safety practices 4 1 How to Prepare the Device for Removing Re installing Modules To prepare the device for removing re installing modules follow these steps in accordance
92. hat come off the right end of the tray as shown in Figure 4 114 then pull them through the right access door as shown in Figure 4 1 Before pushing inserting the tray all the way into the left access door move the two cables you lifted during installation and route them across the left edge with the other cables as in Figure 4 116 oller LEFT VIEW Figure 4 116 Routing Power Supply Cables Before Final Insertion LEFT VIEW 20000 Ielantlsusncs Cani Peronalzston System Hardware Senice anual Page 130 4 Removal and Re installation 4 19 How to Remove Re install the Power Supply Approximate time to remove 15 minutes plus any sub procedures Approximate time to re install 15 minutes plus any sub procedures The power supply receives AC power from the AC power cord plugged in to the rear of the device and converts it to the power levels required by the embedded PC mail logic board and power controller It also reports power status and receive power up and power down commands from the power controller It is located in the rear left of the bottom deck of the device To remove the power supply follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables and security hardware safely disconnected 2 Open th
93. he ASCII Char Font ID 49 1 me 12 If the original embosser had custom characters installed carry them over to the same locations on the new embosser s daisy wheel by following the steps in section 4 10 How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 13 Calibrate the embosser using the information in section 5 4 How to Calibrate the Embosser 14 Power up the device and test it paying special attention to the following 3 Navigate to Menu gt Settings gt Tuning to open the Tuning Move Embossing page pret OOO Ielantlsuancs Cad Personalizar System Hardware Senice anual Page 99 4 Removal and Re installation b Make sure the ribbon information in the upper left corner matches the ribbon you are using If it doesn t set and calibrate the ribbon see the ExpressCard 2000 User Installation and Operation Manual for details c Press th ution The EC2000 will create a test card with all characters and all font IDs d Inspect the card to make sure the embosser is working as expected 15 If the EC2000 does not power up or function properly contact MagTek Support Services for assistance see Appendix A Technical Support pret 2000 TTA Cani Personalizar System Hardware Senice anual Page 100 4 Removal and Re installation 4 12 How to Remove Re install the Tipper Heater Approximate time to remove 15 minut
94. he card holds for a certain amount of time then stops heating and cools down before it pulls the foil off the card If the foil is not being allowed to cool long enough the device may malfunction If the foil is being left to cool for too long the device may be slow or may malfunction A typical Foil Cool Time is 40ms There are no specific calibration steps for adjusting the tipper cooling time 20000 Ielantlsusncs Cad PEATE System Hardware Senice anual Page 177 6 Diagnosis 6 Diagnosis Follow the steps in this section to diagnose reported problems with the EC2000 and determine the appropriate solution 1 Ask the end user for an accurate description of the symptoms and if possible ask them to demonstrate live or via video Understanding the symptoms increases your chances of fixing the problem rather than making it worse 2 Evaluate the device yourself and attempt to reproduce the symptoms Ifthe symptoms are intermittent and you are unable to reproduce them ask the end user to take detailed notes to provide a video recording of the problem or to contact you when the error occurs 3 Go through the steps in the Troubleshooting section of 99875600 ExpressCard 2000 User Installation and Operation Manual 4 If the root cause of the problem is a calibration setting adjust it according to the steps in section 5 Adjustments 5 If you determine the root cause of the problem is a specific part or sub assembly repair
95. ice Manual Page 15 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 Blocked when the hopper transport pushes far enough toward the front of the Exception device that it mechanically rotates to orient with the manual feed slot Hopper Exit Blocked when a card reaches the point where itis 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 Fl 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
96. ides detailed information about maintaining the ExpressCard 2000 EC2000 lt 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 3 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 AI 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 guide If you are performing replacements also gather and inspect available replacement parts 3 Copy software and documents you will need to
97. ighten the remaining loose screws EXCEPT the top rear right you will tighten that after re installing the top access door 18 Re install the top access door by following the steps in section 4 2 How to Remove Re install the Access Door 19 Complete any other service that requires the device to be powered off and open 20 Power up the device and test it paying special attention to the following a Test the touchscreen and manual feed slot light and functionality by creating a sample card from the manual feed slot using the touchscreen b Make sure the device shows Offline on the Biatus page when the top access door is open e Test the electronic latches by testing the remote unlock function GODS Wan ace Cari Stem Radar Serves anual Page 61 4 Removal and Re installation 21 If the EC2000 does not power up or function properly contact MagTek Support Services for assistance see Appendix A Technical Support 20000 Westen Tsuen Cari Personals System Hardware Senice anual Page 62 4 Removal and Re installation 4 8 Howto Remove Re install the Hopper Module Approximate time to remove 30 minutes plus any sub procedures Approximate time to re install 30 minutes plus any sub procedures The hopper module holds the device s card stock hoppers and carries blank card stock to the image printer from the hoppers or from the manual feed slot It is
98. ime to re install 5 minutes plus any sub procedures The top access door is the large lockable door in the top of the cover that secures the user serviceable areas inside the device while allowing users to access and replace consumable items like image printer ribbons and card stock Some service procedures require removing the top access door to give unobstructed access to certain components Figure 4 1 Top Access Door REAR VIEW To remove the top access door follow these steps 1 Unlock the top access door see section 2 7 How to Open the Top Access Door 2 Open the top access door halfway just past the latches on either side of the cover Egress 2000 san ance Cari Fersonalion SM Hardware Serves anual Page 44 4 Removal and Re installation 3 Using both hands gently pull the top cover to the right then slightly upward to free it from its left track as shown in Figure 4 2 Figure 4 2 Pulling the Left Side of the Top Access Door Out of Its Track FRONT VIEW 4 Repeat the process pulling it to the left and slightly upward to free it from its right track 5 Lean the top access door out toward the rear of the device as shown pret 2000 Ielantlsusncs Cani PETRIE System Hardware Senice anual Page 45 4 Removal and Re installation Figure 4 3 Top Access Door Leaning Up and Back FRONT VIEW 6 Move the hopper transport toward the front of the device around ho
99. 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 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 web interface page Express Card 2000 Open the link on the left side of the page to display a File Upload page Press the Browse button to launch the Roose File to Upload dialog box 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 Select the file you want to apply and press the pen button to return to the page Press the andl 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 Restart the device by powering it off then powering it on Wait until the touc displays the ExpressCard 2000 tatus page Inthe 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 screen once again EgremCa OOO TTA TRU Cani Personalizar System Hardware Senice anual Page 28
100. k hoppers inserted and with the device just powered up and ready to process cards the page should match Figure 244 Sensor Utility 0 Qu Qu eA 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 itis 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 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 2000 Tant Card PeronalzsHon Sytem Hardware Sen
101. les then disconnect the cables See Figure 4 121 00D Ielantlsusncs Cari Pernalzston System Hardware Senice anual Page 133 4 Removal and Re installation Figure 4 121 Power Supply Output Cables LEFT VIEW 10 While supporting the power supply with one hand use the No 2 screwdriver to remove the four screws on the bottom of the device s base that hold the power supply gure 4 122 Power Supply Mounting Serews FRONT LEFT VIEW 11 Remove the power supply and set it aside pret Cad Personalizar System Hardware Senice anual Page 134 4 Removal and Re installation re install the power supply follow these steps 1 Put one screw on the tip of the screwdriver hold the power supply in place with one hand and line up the screw holes then loosely screw in the first screw to tack the power supply in place 2 Screw in the remaining screws and tighten all of them 3 Re connect the output wires according to Figure 4 121 4 Plug in the control and monitoring cable 5 Re connect the input wires Insert the spade connectors behind the plate behind the screws not directly behind the screws see Figure 4 119 The connections are as follows 3 The green ground wire goes nearest the floor toward the rear of the device b The black wire goes in the middle c The white wire goes on top toward the front of the device 6 Snap the clear plastic cover back in place
102. lsusncs Cad Peronalaston System Hardware anual Page 117 4 Removal and Re installation 5 Reconnect all remaining cables to the connectors along the right edge of the embedded PC and the power connector near the front edge The connectors are shown in Figure 4 95 Tighten the table s screw posts to secure it in place 6 Continue pushing the embedded PC into the device until the two thumb screws that secure it to the lower deck line up with their holes see Figure 4 93 Do not push it too far in 7 Tighten the thumb screws 8 Tuck the cables back into the space behind the right side access door 9 Close the right side access door by following the steps in section 4 3 How to Remove Re install the Side Access Doors 10 Depending on the situation it may be necessary to complete additional software or hardware configuration steps as directed by your reseller MagTek Support Services or MagTek Engineering BEFORE powering up the device 11 Perform any additional service that requires the device to be powered off and open 12 Close the top access door 13 Re attach the power cable network cable and any security hardware 14 Power up the device 15 From the touchscreen navigate to Menu gt create a sample card and make sure the device functions properly and the sample looks correct Egress GODS Tan ace Cari Fersonalion SM Hardware Serves anual Page 118 4 Removal and Re installation 4 16
103. ment on the EC2000 line at this time 5 7 How to Minimize Image Printer Margins When issuing cards with edge to edge images the width of the margins on the edges of the card is a tradeoff between two factors Customers may desire the thinnest possible margins but if the print head prints too close to the edge of a card the printer ribbon may break Safe margin widths depend on the ribbon type and the specific images and card stock used by the application the image printer is pre calibrated to minimize the margins without breaking ribbons in a majority of applications When possible MagTek recommends using card layouts that are optimized for instant issuance rather than re using designs intended for pre lithographed stock and trying to eliminate the margins by printing 100 close to the card edges and risking ribbon breakage Recommended design techniques include Including the margins as part of the design such as fading images to the card stock color at the edges Pre lithographing border areas including the margins Pre lithographing all areas that are not personalized Designs of this type should account for printer variances by planning either overlaps or gaps between pre lithographed areas and printed images Depending on the application it may be possible to narrow the margins beyond the factory settings by issuing direct commands to the printer until the ribbon breaks with the application s most sensitive break pro
104. mounted to the top deck plate of the device along the right side Figure 4 30 Hopper Module FRONT LEFT VIEW To remove the hopper module follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Remove the cover by following the steps in section 4 4 How to Remove Re install the Cover 3 Move the hopper transport to the front of the device just past hopper 7 and before it rotates to the manual feed slot see Figure 4 31 and section 2 8 How to Safely Move Transports By Hand Egress Card Personam Sa Radar Serves anual Page 63 4 Removal and Re installation 4 Remove all the card stock hoppers and set them aside in a secure location or give them to the 5 7 8 customer for secure temporary storage Figure 4 31 Save Removal Location for Hopper Transport TOP VIEW FROM FRONT Disconnect the two sensor cables from the rear right of the hopper deck see Figure 4 32 Look at the labels or colors of each cable noting which cable is plugged in to the connector closer to the front and which is plugged in to the connector closer to the rear Figure 4 22 Two Hopper Module Sensor Cables FRONT RIGHT VIEW Locate the HOPPER SHUTTLE breakout circuit board mounted to
105. nches and dies on the daisy wheel Both hammers have a small round plate with a hole that lines up with a cone on each character The cone on each character should be sharp and unbent and must line up properly with the hole in the hammer Figure 3 7 shows a magnified view of a properly aligned hammer above and die below viewed from the front of the embosser Because it can be difficult to see the front of the embosser module with the EC2000 s cover and other modules installed it is best to inspect the cones with an inspection mirror Section 3 12 2 provides further detail Figure 3 7 Embosser Hammer and Character FRONT VIEW Egress GODS san ance Cari Sam Hardware Serves Mana Page 39 3 Preventive Maintenance 3 12 2 How to Service the Embosser Module Service the embosser by following these steps If you discover any issues you can not resolve contact MagTek Support Services to procure a replacement embosser module 1 Use compressed air to clean the embosser bridge the metal block between the daisy wheels that supports the indent cartridge ribbon 2 Inspect the top and bottom embosser daisy wheels for missing or worn characters and replace them if possible see section 4 10 How to Remove Re install Embosser Fonts After installing make sure the tine is still intact and holds the character tightly Inspect the top and bottom embosser daisy wheels for missing bent or broken tines Install any
106. ne card design then widening the margin adjustment by a few pixels The margin sizes are based on four values The X left right position of the image relative to the left edge of the card Y up down position of the image relative to the top of the card The X size length of the image with additional rows added at the right edge of the card The Y size width of the image with additional rows added at the bottom edge of the card Egress GODS Wan ac Cari Sstem Hardware Serves anual Page 172 5 Adjustments To minimize the image printer s unprinted margins follow these steps 1 Navigate to Menu gt Bettings gt Printer gt Advanced to open the Printer Uli page 2 Press the Print Tech Card button and follow any on screen instructions to print a card that shows the current image printer settings which you will use later in this process The first two values of the X Y Smart Offsets row provide the current Rx and Ry settings and the Printed Lines LW line provides the current Ral and Rnw settings 3 Press the button to open the Printer Utt page 4 Select the Command text box Use the on screen keyboard and the Bend button to send all the commands in the following steps to the image printer and monitor the printer s responses in the Response text box Note Commands are case sensitive You must use the shift key to capitalize the first letter of each command 5 Lower
107. ness of its embossed characters Section 5 4 3 How to Measure Embossed Character Thickness provides step by step instructions 54 2 How to Callbrate the Embosser Wheel Home Position To make sure the motor controller accurately centers the embosser wheel in the embosser bridge opening follow these steps 1 Close the EC2000 top access door to make sure no light will interfere with the sensor 2 Inthe ExpressCard 2000 Utility Navigate to Menu gt Settings gt Service gt MCP Commands open the Eontrolier Commands page 3 Press Calibrate Wheel Home button and wait for 10 seconds until the embosser stops moving The system will fll in a value below pret OOO TTA TRU Cani Personalizar System Hardware Senice anual Page 149 B Adjustments 4 8 sega aleme home _ Entomol _ vana _ Coruna warmer _ Entons n04 Pesh To Roar Ta imei _ sume erwin Prat Eject clamp cara Repeat the Calibrate Wheel Home operation several times until you see the same number three times in a row If the number continues to change after 10 tests report the unit s failure to calibrate Check that the value below Balibrate Wheel between 4 and 10 1f the value is not in that range report the unit s failure to calibrate within the acceptable range
108. ning to open the Tuning Wave Embassing page 4 Make sure the ribbon information in the upper left corner matches the ribbon you are using I it doesn t set and calibrate the ribbon see the ExpressCard 2000 User Installation and Operation Manual for details 5 Turn on the Color checkbox if the ribbon is YMCKO or YMCKOK 6 Calibrate the Card X Offset and Card Y Offset settings which changes the position of all fonts a Press the button The EC2000 will create a test card with all font IDs b Look only at the first character of the long string of letters at the bottom of the card Font ID2 from all angles and determine whether the embossed character is to the left right above or below the printed character Tuning Move Embossing ribbon Gr 9234 5618 4012 345b 0123856709 E Orginal Ancor morons E New TTE CC 4 Cord X Offset 3 c Ifthe embossed character appears to the left of the printed character increase the Card X Offset setting and press the ave button d Ifthe embossed character appears to the right of the printed character decrease the Card X Offset setting and press the Bave button Ifthe embossed character appears higher than the printed character decrease the Card Y Offset setting and press the ava button f Ifthe embossed character appears lower than the printed character increase the Card Y Offset setting and press the B
109. nstall 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 4 78 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 gt create sample card and make sure the device functions properly and the sample looks correct 17 Return the tipper heater and report form to MagTek for recycling GODS Wan ace Cari Fersonalion Serves anual Page 105 4 Removal and Re installation 4 13 How to Remove Re install the Tipper and Exit Ramp Module Approximate time to remove 15 minutes plus any sub procedures Approximate time to re install 15 minutes plus any sub procedures The tipper exit ramp module receives cards from the exit transport module stamps them with heat fused foil from the tipper foil roll then moves them to the card output hopper on a cushion of air It is located in the front middle of the top deck plate just to the rear of the card output hopper 2X 46500154 48310000 4x 0 6X 48325000
110. nstalling Modules At the end the device should be powered down with all external cables safely disconnected 2 Open the top access door by following the steps in section 2 7 How to Open the Top Access Door 3 Locate the magnetic stripe reader module behind the curve at the top front of the cover 4 Open the image printer to make room for the screwdriver you will use in the next step 5 Use the No Philips screwdriver to remove the right and middle screws securing the MSR to the cover Note the screws are installed at a slight downward angle See Figure 4 123 Figure 4 123 Magnetic Stripe Reader Screws REAR LEFT VIEW 6 Close the image printer and remove the left and final screw securing the MSR to the cover 7 Ifthe MSR cable is tied or clipped to the front of the cover untie or unclip it Leave any ties or clips on the top deck plate in place 8 Pull the MSR out of the cover and disconnect its cable 9 Set the MSR aside pret 2000 Ielantlsusncs Cari PEATE System Hardware Senice anual Page 136 4 Removal and Re installation re install the magnetic stripe reader MSR follow these steps 1 Re connect the MSR cable 2 Press the MSR back in place see Figure 4 123 Open the image printer to make room for the screwdriver you will use in the next step 4 Use the No 1 Philips screwdriver to re insert and tighten the right and middle screws 5 Close the image printer and re insert and
111. o remove 5 minutes plus any sub procedures Approximate time to re install 5 minutes plus any sub procedures The side access doors secure the control electronics embedded PC power supply power controller and main logic board inside the device right side access door gives easy access to the embedded PC s connectors including Ethernet and USB poris for example to plug in a keyboard mouse or USB thumb drive and also provides access to examine or replace the Main Logic Board MLB The left side access door provides access to the power supply and the power controller board sometimes referred to as the Green controller It is less common to need to open the left side access door raa Figure 4 6 Left and Right Side Access Doors REAR VIEW To open the side access doors follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules 2 Move the hopper transport to the front of the device near the manual feed slot see section 2 8 How to Safely Move Transports By Hand This helps avoid damaging the hopper transport ribbon cable when removing the right rear thumb screw If you are removing the left access door lift the left side of the 2000 and prop up the two left rubber feet on a card weight atop a soft cloth or piece of cardboard Be sure card weights do not stick past the rubbe
112. of the hopper module plugs into the right connector labeled EXC HOME SENS Egress 2000 Tan ance Cari SM Serves anual Page 73 4 Removal and Re installation Figure 4 48 Sensor Cables Plugged In To HOPPER SHUTTLE Circuit Board FRONT VIEW 19 Plug the two sensor cables at the rear of the device into the two plugs on the circuit board at the top reat right of the hopper module The cable labeled to J2 goes to the REAR plug and the cable labeled t0 11 goes to the FRONT plug See Figure 4 49 Figure 4 49 Sensor Cables at Rear of Hopper Module RIGHT VIEW 20 Loop the hopper transport drive belt around the gear of the hopper drive motor at the rear of the device as shown in Figure 4 50 pret Cani Personalizar System Hardware Senice anual Page 74 4 Removal and Re installation Figure 4 50 Attaching Hopper Transport Drive Belt FRONT RIGHT VIEW 21 Use the 5 32 Allen wrench to insert and tighten the four screws that secure the hopper module to the top deck plate see Figure 4 30 at the beginning of this section 22 Use the 5 32 Allen wrench to tighten the belt tensioner screw on the front of the hopper module see Figure 4 37 so the top and bottom of the drive belt are parallel with each other and the belt feels tight to your fingers During testing the belt should not slip or make grinding sounds If it does the tension
113. on Vetify This Happens Hopper transport s pusher moves into safe position for move Hopper Hopper transport moves to or stays at manual feed slot slot light flashes Hoppe Hopper transport moves to or stays at hopper 1 slot light stops flashing Hopper Hopper transport moves to or stays at hopper 1 B Hopper transport moves to or stays at hopper 1 Manual Feed Hopper transport moves to or stays at manual feed slot slot light flashes Hoppe Hopper transport moves to or stays at hopper 1 Hopper transport moves to or stays at hopper 1 Hopper transport moves near hopper 1 2000 etant Cani Personalston System Hardware Sanies anual Page 12 2 Introduction Press This Button Verify This Happens Hopper Hopper transport moves to or stays at hopper 1 Hopper Hopper transport moves to or stays at hopper 1 Bot Cartridge Unload Rear black indent cartridge moves out of embosser toward rear of device Bot Cartridge Load Rear black indent cartridge moves back into embosser loi Cartridge Home indenter Move ui Rear black indent cartridge moves back into or stays in embosser Bot Cari to Indeni Rear black indent cartridge moves between letters on embosser wheel Bot Ribbon Advance indenter Move Ribbon in rear black indent cartridge advances by about 77 Cartridge Unload
114. or which is connected to the rear right corner plug See Figure 4 91 5 Use a slotted screwdriver or equivalent tool to pry the sides of the connector out of the plug then gently disconnect it Avoid pulling directly on the wires Figure 4 91 Exit Transport Wire Tether TOP VIEW FROM FRONT 6 Use the 1 8 Allen wrench to remove the four screws and washers that secure the corners of the exit transport module to the top deck plate shown in Figure 4 90 and set the screws aside 7 Carefully lift the exit transport module out of the device making sure no wires catch on it and set it aside re install the exit transport module reverse the steps for removing it making sure not to squeeze any wires between the module and other parts of the device After re installing the module follow these steps 1 Perform any additional service that requires the device to be powered off and open 2 Re install the cover and top access door by following the steps in sections 44 and 4 2 respectively 3 Close the top access door 4 Re attach the power cable network cable and any security hardware 5 Power up the device 6 From the touchscreen navigate to Menu create sample card and make sure the device functions properly and the sample look 20000 Ielantisusncs Cani Personalizar System Hardware Senice anual Page 112 4 Removal and Re installation Approximate time to remove 15 minutes
115. or replace it according to the steps in section 4 Removal and Re installation 6 1 Known Symptoms and Possible Causes This section contains additional supplemental symptoms and possible causes that are not covered in the end user documentation either because they would generally only appear after servicing the device or because they can not be addressed by the user 6 11 Error message Card Jam at roller station Use page to test hopper transport movement and card stock feed 6 12 Hopper transport does not move Make sure the cables below the hopper are plugged in to the right connectors in the connector panel on the top deck plate It is possible to accidentally reverse cables that go to similar connectors If the hopper transport moves but does not pull cards check the flex cable that connects the breakout board on the top deck plate to the hopper transport The cable can come loose if it is accidentally bumped during re installation of the cover 6 13 Uneven Tipping If the foil tipping on the front of the card is uneven and can not be fixed by re calibrating the tipper module see section 5 8 How to Calibrate the Tipper Module itis possible the tipper heater needs to be replaced See section 4 12 How to Remove Re install the Tipper Heater Egress BODO Tan ance Cari Personalan SM Hardware Serves anual Page 178 Appendix B Technical Support Appendix A Phone 651 415 6800 Free 888
116. ort Services for a replacement prea 00D Ielantlsusmcs Cad Personalizar System Hardware Senice anual Page 33 3 Preventive Maintenance 3 7 Service the XY Transport Module Do not lubricate the EC2000 s gears or bearings They are made of self lubricating powder metal and lubricants can damage their surfaces Follow these steps to lubricate the one shaft that requires lubrication Do not use Tri Flow lubricant on any shaft other than the one shown below 1 1f there is dirt dust or debris on the XY transport rods wipe it off using a sofi lint free cloth 2 Use the MEP Commands page see section 2 9 1 How to Use the MCP Commands Page to move the XY transport from the front to the rear of the device to verify the movement is smooth and there is belt slippage Leave the transport at the rear of the device 3 Check the XY transport drive belt for any signs of damage If it is damaged contact MagTek Support Services for a replacement 4 Stand at the front of the device and locate the XY transport shaft closest to the image printer It is the only shaft that has a blue bearing around it see Figure 3 5 Figure 3 5 Blue Bearing On XY Transport FRONT LEFT VIEW 5 Shake the bottle of Tri Flow lubricant and remove the cap 6 Run a thin 3 4 inch long bead of Tri Flow along the top of that one shaft Egress GODS Wan ace Cari Parona EAOn SM Hardware Serves anual Page 34 3 Preventive Maintenance
117. ort as described in the previous section Navigate to Menu gt Bettings gt Service gt MCP Commands to open the Eontroller Commands page Press the KY To Embosser button Press the button Make sure the XY Transport does not bump against the Exit Transport Make sure the first green roller on the exit ramp is centered on the card Make sure the card is pushed into the exit ramp past the point where the first green roller touches it Ifthe card doesn t fit all three of these conditions adjust the handoff location by following these stes 3 Navigate to Menu gt Bettings Edit Config to open the first Configuration Editing password page 2000 Itantlsusncs Cad Personalizar System Hardware Seice anual Page 146 5 Adjustments by E E E DI hy i Enter password 1238887 and press the E button to open the second password page Enter password 7684321 to open the Configuration Editing page Scroll down in the list of settings until you find the ExitHandoffA djustmentX setting IF the XY Transport bumped into the Exit Transport decrease the ExitHandoffAdjustmentX setting by selecting the number in the list pressing the button then entering the new number on the on screen keypad and pressing the E button Adjust about 10 steps at a time IE the card did not push far enough into the exit ramp inerease the ExitHandoffAdjustmentX setting by selecting the number in the
118. out the right side of the tipper Figure 4 83 Removing Re inserting the Tipper Heater TOP VIEW FROM FRONT GODS Wan ace Cari Serves anual Page 104 4 Removal and Re installation 11 Determine the number of cards the tipper heater has produced and record the number on the EC2000 Preventive Maintenance Checklist included with the replacement kit 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 4 83 2 Run the cable out the front of the tipper as shown in Figure 4 77 and Figure 4 80 3 Hold the tipper heater up in place with one hand as shown in Figure 4 82 4 Insert and hand tighten the right spring loaded post making sure it holds the tipper heater up Figure 4 84 Hand tightening the First Spring loaded Post RIGHT VIEW 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 4 81 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 4 80 9 Re connect the tipper heater cable to the plug on the left side of the tipper see Figure 4 79 10 Re i
119. ove Re install the Top Access Door How to Remove Re install the Side Access Doors How to Remove Re install the Cover How to Remove Re install the Hopper Module How to Remove Re install the Image Print Head How to Remove Re install the Image Printer Module How to Remove Re install the XY Transport Ribbon Cable How to Remove Re install the XY Transport Modul How to Remove Reinstall Embosser Font How to Remove Reinstall the Embosser Module How to Remove Reinstall the Tipper Heater How to Remove Reinstall the Tipper and Exit Ramp Module How to Remove Reinstall the Exit Transport Module How to Remove Reinstall the Embedded PC How to Remove Reinstall the Embedded PC Solid State Drive SSD How to Remove Reinstall the Main Logic Board MLB How to Remove Reinstall the Power Controller and Backplane How to Remove Reinstall the Power Supply How to Remove Reinstall the Magnetic Stripe Reader MSR Module How to Remove Reinstall the Touchscreen ExpresCard 2000 Tata lsuance Car Personaalia System Hardware Senice Manual Page 5 1 Table of Contents Appendix Key Loading 20000 Wate Tsuen Cari Personalna System Hardware Senice anual Page 6 1 Required Tools Materials and Documents 1 Required Tools Materials and Documents 1 1 Required Tools Part Number Quantity Description 33011008 T
120. oving a Character from the Embosser Module Daisy Wheel To remove a character from a tine on the embosser module s daisy wheel follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Insert an X Acto knife between the tine and the character as shown in Figure 4 70 3 Carefully pry the character toward the ceiling until you can remove it with your fingers 4 Prepare the character for installation in the new time by making sure it is oriented correctly 5 Support the tine then press the character into place with your fingers 6 Notify the EC2000 s software that the character has moved For detailed instructions refer to section 2 9 4 How to Use the Character Mapping Page pre 00D aiant TRU Cad PeronalzsHon System Hardware Senice anual Page 93 4 Removal and Re installation 4 11 How to Remove Re install the Embosser Module Approximate time to remove 15 minutes plus any sub procedures Approximate time to re install 30 minutes plus any sub procedures The embosser module located at the front left corner of the device punches raised and indented characters into cards as they are held by the XY transport i 146500154 4X I 1 48325000 4X 83070819 N Figure 4 71 Embosse
121. p penton access door Open side access doors Revove foreign objects pea mechani Creckrevsion numbers Uplate MID rv Update nter Wewre appropriate Clean f apropiate ione aporoprote Gean card cleaning roller Dem mage printhead Chace landat aira ater tating inset for missing worn characters Senden embosser made Inspector missing broken bee bent broken cones EET Replace racers as appropriate hack nore depth wu 2000 WT Cani PEATE System Hardware Senice anual Page 24 3 Preventive Maintenance 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
122. plus any sub procedures Approximate time to re install 15 minutes plus any sub procedures The embedded PC provides the user interface on the EC2000 s touchscreen and connects to the Main Logic Board MLB to communicate with sensors and motors within each of the device s modules It is located in the rear right of the lower deck tub in the device and is mounted to a tray that slides into two tracks built in to the bottom of the lower deck Figure 4 92 Embedded PC TOP VIEW FROM REAR To remove the embedded PC follow these steps 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Open the right side access door by following the steps in section 4 3 How to Remove Re install the Side Access Doors 3 Locate the embedded PC behind the right side access door toward the rear of the device 4 Loosen the two thumb screws securing the embedded PC tray to the lower deck see Figure 4 93 until they pop up Do not attempt to remove them from the tray 20000 Ielantlsusncs Cad PEATE System Hardware Senice anual Page 113 4 Removal and Re installation Figure 4 93 Embedded PC Thumb Screws RIGHT VIEW 5 Use the finger holes to slowly and carefully pull the embedded PC out just far enough to make the connectors
123. pper 6 see section 2 8 How to Safely Move Transports By Hand 7 Remove card stock hoppers 1 and 2 8 Locate the screw and washer that fasten the cover to the metal plate on the rear of the base The fastener can be found in the rear upper right of the device behind hopper 1 as shown in Figure 4 4 Figure 4 4 Removing the Right Side Cover Screw Near Top Access Door Hinge FRONT LEFT VIEW 9 During the next step hold the top access door with one hand or it may fall or break 10 Use the No 2 Philips screwdriver to loosen the fastener 11 Remove the top access door and set it aside with the two screws and washers if necessary move the XY transport out of the way per section 2 8 How to Safely Move Transports By Hand Egress GODS san anc Card System Radar Serves anual Page 46 4 Removal and Re installation 12 Remove the bushings from the top cover s two hinges one on each side and set them aside with the cover and the two screws and washers Figure 4 Top Access Door Hinge Bushings FRONT LEFT VIEW re install the top access door reverse the steps for removing it Be careful not to lose the door s bushings which are not secured to the cover or to the top access door s hinges pret 00D Teta Cani PETRIE System Hardware Seice anual Page 47 4 Removal and Re installation 4 8 How Remove Re install the Side Access Doors Approximate time t
124. printed character increase the Font IDI X Offset value and press the Save button d I embossed character appears to the right of the printed character decrease the Font IDI X Offset value and press the Save button Ifthe embossed character appears higher than the printed character inerease the Font IDI Y Offset value and press the Save button f Ifthe embossed character appears lower than the printed character decrease the Font ID1 Y Offset value and press the Save button g Repeat the process until the embossed and printed first character of Font IDI is aligned 10 Repeat the same process for Font ID2 looking only at the first character of the long string of letters at the bottom of the card 11 Repeat the same process for Font ID3 if installed looking only at the first character of the string of frontindented characters 12 Repeat the same process for Font ID4 looking only at first character of the string of digits on the rear of the test card IMPORTANT NOTE Because Font ID4 is on the rear of the card adjust the Font ID4 X Offset in the opposite direction than for other fonts where the instructions say increase decrease the value instead pret OOD Inantlsusncs Cani Personalizar System Hardware Senice anual Page 162 5 Adjustments Look at the FIRST number of Font 1 1 PAN Adjust Font 101 X Offset Font ID1 Y Offset Repeat for Font 102 Font 103 Font ID4 Font IDI X Offset Fon
125. ps down toward the printed circuit board and pinch to lock them in place pre 00D ETE TETAS Cad Personalizar System Hardware Senice anual Page 86 4 Removal and Re installation 6 Move the XY transport to the rear of the device see section 2 8 How to Safely Move Transports By Hand and inspect it to make sure it looks like Figure 4 38 7 Use the belt to push the XY Transport back and forth across the full length of the rails to make sure the ribbon cable moves asit should a The ribbon cable should wind and unwind in a straight line it should not twist bend diagonally or move to the side b The ribbon cable should not contact any objects in its path Ifthe ribbon cable touches other parts bends incorrectly re check its connections and orientation according to the installation steps then 8 Complete any other service that requires the device to be powered off and open 9 Close the top access door 10 Re attach the power cable network cable and any security hardware 11 Power up the device 12 From the touchscreen navigate to eng gt a sample card and make sure the device functions properly and the sample looks correct 000 Ielantlsusncs Cad Personalizar System Hardware Senice anual Page 87 4 Removal and Re installation 4 9 Howto Remove Re install the XY Transport Module Approximate time to remove 15 minutes plus any sub procedures Approximate time
126. r Module FRONT RIGHT VIEW To remove the embosser module follow these steps 1 Power on the device and open the top access door 2 From the touchscreen navigate to Menu gt Maintenance to open the Maintenance Menu page 3 If the device has a top indenter press the Unload Cartridge button under Indent Cartridge io move the front indent cartridge into the unload position Remove the top indent cartridge and set it aside in a secure location or give it to the customer for temporary storage or secure disposal prea 0000 Tan TRU Cani Peronalzston System Hardware Senice anual Page 94 4 Removal and Re installation 4 Press the Unload Cartridge button in the Bottom Indent Cartridge section to move the rear indent cartridge into the unload position Remove the rear indent cartridge and set it aside in secure location or give itto the customer for temporary storage or secure disposal 5 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 6 Remove the cover by following the steps in section 4 4 How to Remove Re install the Cover 7 Carefully disconnect embosser s cable from the top deck making sure not to break any wires Figure 4 72 shows the cable as seen from the left side of the device er a Figure 4 72 Embos
127. r feet toward the left edge of the device Alternatively you may move the EC2000 to the edge of the work surface so the left side of the device hangs 1 over the edge This will make it easier to remove the left access door and will protect the surface you are working on Figure 47 Propping Up the 2000 Feet LEFT VIEW 4 Open the top access door see section 2 7 How to Open the Top Access Door 5 Using a flashlight locate the two thumb screws in the base plate on the side you want to open These screws lock into holes on the top of the side access door and hold it in place 0000 Ielantlsusncs Cad Peronalzston System Hardware Senice anual Page 48 4 Removal and Re installation 6 Being careful not to pinch any cables or wires between the screwdriver and the screw use the long No 2 Philips screwdriver to unscrew the two thumb screws 7 Lower the side access door to free its bottom tabs from the cover remove it and set it aside see Figure 4 8 Figure 4 8 Removing the Left Side Access Door FRONT LEFT VIEW To close the side access doors follow these steps 1 Orient the side access door straight up and down like it will be on the EC2000 cover 2 Slide the side access door s locking tabs into their slots on the bottom of the EC2000 s cover You may need to move it forward and back along the cover to find the place where the tabs insert 3 Hold the side access door up in place with one han
128. r to be removed 6 Recinstall the cover by following the steps in section 4 4 How to Remove Re install the Cover 7 Remember to secure the touchscreen cables with silicone as shown in Figure 4 127 Figure 4 127 Silicone Adhesive On Touchscreen Connectors REAR VIEW 8 Perform any other service that requires the device to be powered down and open 9 Close the top access door 10 Re connect the power cable network cable and any security hardware 11 Power up the device 12 Use the touchscreen to navigate through several menus to make sure it functions properly 13 Perform any relevant adjustments from section 5 Adjustments notably section 5 1 How to Calibrate the Touchscreen preva 2000 Ietantlsusmcs Cad Personalizar System Hardware Senice anual Page 140 5 Adjustments 5 Adjustments During scheduled maintenance or after replacing module testing may reveal that the settings for one or more ofthe modules in the EC2000 need to be adjusted This section is intended to be used as a reference only when needed and provides step by step instructions for adjusting calibration settings 5 1 How to Calibrate the Touchscreen If finger presses on the touchscreen are registering in the wrong place for example after replacing the touchscreen follow these steps 1 Contact MagTek Support Services for assistance signing in to the device as an administrator and accessing the Windows desktop 2 Stand in front o
129. ransport 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 Ifa 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 Egress GODS san ac Cari System Radar Serves anual Page 11 Introduction 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 itis 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 Bettings Menu page
130. read the current setting for the Y position b Use the Py ynumber command where number is 1 4 steps smaller than the Y value reported by Ry to bring the top edge of the image closer to the top edge of the card Create a set of test cards that represent the full range of the application s images d test cards are created successfully repeat the process of raising the Y position e Ifthe test cards show wrinkled edges or other problems raise the value closer to where it was to start and re try test cards until they are created successfully 8 Increase the Y size height of the image on the card by following these steps a Use the Rnw command to read the current setting for the Y size b Use the Pnw number command where number is 1 4 steps larger than the original value reported by Ral to add rows to the bottom edge of the image bringing it closer to the bottom of the card Create a set oftest cards that represent the full range of the application s images d test cards are created successfully repeat the process of increasing the Y size 2000 san anc Cari System Radar Serves anual Page 173 5 Adjustments e Ifthe test cards show wrinkled edges or other problems lower the value closer to where it was to start and re try test cards until they are created successfully 000 Wate Tsuen Cani POTATO System Hardware Senice anual Page 174 5
131. rench to unscrew the four screws and washers that attach the four corners of the image printer to the top deck plate see Figure 4 51 10 Use both hands to carefully the printer out of the device making sure no cables catch on it as you remove it Set it aside ET 20000 TTA Cani PersonalzsHon System Hardware Senice anual Page 79 4 Removal and Re installation To re install the image printer module follow these steps 1 Clear all cables out of the way to make room on the top deck plate for the replacement image printer 2 Carefully lower the replacement image printer tilted slightly downward toward the hoppers and line up the screw holes in its base with the screw holes in the top deck plate 3 Make sure the downward facing sheet metal tabs in the base of the image printer insert into the corresponding slots on the top deck plate see Figure 4 55 You may have to push a bit on the sheet metal of the image printer s base to line up the tabs Figure 4 55 Seat Image Printer Tabs In Slots TOP RIGHT VIEW 4 Use the 5 32 Allen wrench to re fasten the screws and washers that secure the image printer to the top deck plate see Figure 4 51 5 Re connect the power cable reconnect the card exit sensor and reconnect the USB cable to J31 OOO Ieantlsusmcs Personalizar System Hardware Senice anual Page 80 4 Removal and Re installation Figure 4 56 Re conne
132. ribbon follow the steps in this section to re align the indenter 5 5 2 How to Callbrate the Rear Indent Cartridge Positions To calibrate the indent position of the indenter follow these steps 1 Create a sample card using sample 3 in Menu gt 2 Navigate to Menu gt Bettings gt Serviee gt Cmds to open the Eaniraller Commands page TERRES 2000 instant stance Card Personalization System Hardware Serves anual Page 164 5 Adjustments 3 Under the Indenter Move button select Bot Cartridge Unload in the dropdown list Controller Commands MAGTEK ee Gawa ET Siere jussus _ Emboss riot mmu anui Imensas Sotto UE TEE SS p Controller Commands tbe Yo Hone To ened Feet E TC ERE NES Jessen reete Frey canna Tene coats _ Entornos rursum ESS p E eee en SAT manasa Se 5 Look at the up down position of the negative letters or numbers removed ink on the indenter ribbon They should be centered between the top edge and bottom edge of the ribbon 6 Hf they are not centered a Navigate to Menu gt Bettings Edit Config to open the Configuration Editing password age b Enter password 234867 press the E button c Enter password 7654321 and press the E button d
133. rinter 2 Open the image printer and clean its interior if necessary Dust and other particles are attracted to the image printer ribbon or card stock by static produced during image printing and can contaminate image printed cards causing spots or speckles 3 Clean the card cleaning roller and replace it if necessary see 99875600 ExpressCard 2000 User Installation and Operation Manual for details 4 Clean the image print head with head cleaning pen see 99875600 ExpressCard 2000 User Installation and Operation Manual for details 5 Check handoff from image printer to XY transport Adjust if needed see section 5 3 2 How to Calibrate Printer to XY Transport Handoff pret 20000 Ielantlsusmcs Cani Personalizar System Hardware Senice anual Page 38 3 Preventive Maintenance 3 12 Service the Embosser Module 3 2 1 About Servicing the Embosser Module The embosser module presses characters into card stock by squeezing the card between a raised metal letter called punch and an indented letter of the same shape called a die installed on the embosser s top and bottom daisy wheels For indented characters the die is replaced with a flat metal plate so the card stock is only altered on the character side Worn out punches or dies can produce characters of poor quality or characters that are raised indented less than the required depth The top and bottom embosser motors each drive a hammer that applies force to the pu
134. s 1 Install YMCKO ribbon see the ExpressCard 2000 User Installation and Operation Manual 2 Inthe ExpressCard 2000 Utility navigate to Menu gt Settings gt Printer open the page 3 Press the Auto Detect amp Configure Ribbon button The system will show Detecting Ribbon on the button until the process is complete 4 When the system pops up a dialog box reporting Ribbon YMCKO was successfully detected and configured press the DK button Egress GODS san issuance Cari Sstem Hardware Serves anual Page 167 5 Adjustments Printer Utility Peres OSES WS Dine Mote DUPLEX CC pra ca mii mere Printer Utility Rasra ws cried Due Mote OUPLEX CE emnes seruos a Fent 6 Press the Color Sen Ad button 7 Wait about 10 seconds and listen for the printer to stop moving Egress GODS san issuance Cari Fersonaion System Radar Serves Manual Page 168 5 Adjustments Printer Utility MAGTEK Pe Tipe Kosk IMS cose tjet Cad m eam 8 Press the Commands button The device will pop up a dialog box advising you that sending commands will require password Press the DK button to launch the first password page Egress 2000 san issuance Cari Fersonaion Stem Hardware Serves anual Page 169 5 Adjustments Printer Utility Pun pe OSE pm Dies DUPLEX O e
135. s pressure allows the justifier to straighten the card against the XY tansport s card clamp If the XY transport needs to be calibrated follow the steps in this se 5 3 2 How to Calibrate Printer to XY Transport Handoff calibrate where the XY transport goes to take a card from the printer follow these steps 1 Navigate to Menu gt Bettings gt Service gt MCP Commands to open the Controller Commands page 2 Press the Pusher Home button 3 Press the Shuttle Home button 4 Next to the To Hopper button select i from the list and press the FS Hoppar button 5 Press the button 6 Press the bution 7 Press the KY Home button 8 Press the button 9 Press the button 10 Press the button 11 Press the button 12 Press the button 13 Press the button 14 Make sure the card reaches far enough out of the printer that sticks out just past the second metal block on the card clamp assembly both metal blocks are circled in Figure 5 1 15 Make sure the card touches the back of the black plastic part of the card clamp all along the line shown in Figure 5 1 16 Make sure the card is pushed far enough toward the front of the device that it pushes on and raises the metal justifier flag next to the printer exit even just a little bit is OK 0000 Teta Cari Personalizar System Hardware Senice WENET Page 145 B Adjustments Figure 5 1 Card Clamps On Card
136. se the 5 32 balL end Allen wrench to re fasten the three screws that attach the indenter module to the embosser module 5 Route the embosser cable along the left wall of the device then under the XY transport belt and rails as shown in Figure 4 72 6 Plug the embosser cable back in to its connector on the top deck plate Press firmly on the two metal sides of the connector to make sure it is seated tightly 7 Perform any additional service that requires the device to be powered off and open 8 Re install the cover and top access door by following the steps in sections 44 and 4 2 respectively 9 Re attach the power cable and network cable and power the device 10 Use the tools found in Menu gt Maintenance to re install any indent cartridges you removed at the beginning of these steps Install the original cartridges or obtain new ones from the customer 11 If you have installed new embosser with all characters in factory default locations and if the customer has no custom characters installed wait until other service is complete and the device is ready to power up then reset the character mappings in the touchscreen software as follows 3 From the touchscreen navigate to Menu gt Bettings Service Wheel Map to open the first Wheel Mapping password page b Enter password 8887890 and press the E key to open the second Wheat Mapping password page c Enter password 0987654 and press the E key to open the page d Press t
137. ser Cable TOP VIEW FROM LEFT 8 Re route the embosser cable so the connector rests on top of the XY transport rails as shown in Figure 4 73 pear 2000 Teta Cani Personalizar System Hardware Senice anual Page 95 4 Removal and Re installation Figure 4 73 Safe Removal Position for Embosser Cable TOP VI FROM LEFT 9 In each of the following steps rotate the embosser daisy wheel so only empty tines are near the Allen wrench This saves time if the wrench slips and breaks a tine if the broken tine were not empty you would have to re install the font to another tine and re map it in the software 10 Use the 5 32 ball end Allen wrench to remove the three screws that attach the rear indent module to the embosser The left image in Figure 4 74 shows two screws as seen from the left side of the device and the right image shows the final screw as seen from the rear of the device Figure 4 74 Unfastening Rear Indent Module TOP VIEW FROM LEFT and TOP VIEW FROM REAR 11 Use the 5 32 ball end Allen wrench to remove the four screws and washers that attach the embosser to the top deck plate and set them aside The left image in Figure 4 75 shows two screws as seen from the front of the device and the right image shows the other two as seen from the rear of the device ET 20000 Teta Cad PETRIE System Hardware Senice anual Page 96 4 Removal and Re installation
138. ss 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 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 careful 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
139. ssary to complete the test 2000 Instant lsuance Car Personalna System Hardware Senice anual Page 18 2 Introduction 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 AIT Motors Stop button to make sure the daisy wheel motor is not energized holding still 6 Press the Status button to retum to the Btatus page 2 9 3 3 How to Move the Embosser Cams Hammers The top and bottom embosser cams which can be driven by the button and Bottom Clamp Motor Move butions squeeze the embosser hammers to imprint raised characters on cards Ina 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 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 page 1 Press the Motors Stop button to make sure no motor is applying force 2 If there is nothing in the way of the hammers press the 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 sur
140. stallation Figure 4 97 Connectors On Left Half of Embedded PC TOP VIEW FROM RIGHT 10 Make sure there are no cables connected to the embedded PC set it aside on a suitable work surface and remove any remaining adhesive 20000 TT Cani Personalizar System Hardware Senice anual Page 116 4 Removal and Re installation re install the embedded PC reverse the steps you followed to remove it 1 Re connect the cables that attach to the left half of the embedded PC see Figure 4 97 including at least two ribbon cables connected to COMI and COM2 and one ribbon cable connected to the multi colored front panel connector 2 Ifyou have connected one or more cables for magnetic stripe readers identified by a label calling out Molex headers or by being connected to a header labeled as USB apply silicone adhesive along the right edge of each connector to hold it in place as shown in Figure 4 98 Figure 4 98 Silicone Adhesive On MSR Connector RIGHT VIEW 3 Line up the embedded PC tray with its tracks on the bottom of the lower deck see Figure 4 99 Figure 4 99 Tracks for Embedded PC and Main Logie Board RIGHT VIEW 4 Carefully push the embedded PC back into the device until only the connectors along its right edge are exposed see Figure 4 94 While pushing use a flashlight and other tools as appropriate to make sure its cables do not snag inside the device pret 00D Ielant
141. t IDI X Offset ont IDLY Offset T 7 Font IDI Y Offset 1 Font ID1 Y Offset 1 Font IDI X Offset Finished Font IDI X Offset 1 Font IDI X Offset Font IDI X Offset Font ID1 Y Offset 1 Font IDI Y Offset 1 Font Y Offset 13 Calibrate the Font IDI X SPT and Font IDI Y SPI steps per inch settings b 9 E E E Press the Prini button The EC2000 will create a test card with all font IDs Look only at the last character of the PAN Font ID1 from all angles and determine whether the embossed characteris to the left right above or below the printed cha Press the Advanced button to open the page If the embossed character appears to the left of the printed character increase the Font IDI steps per inch adjustment and press the Save button If embossed character appears to the right of the printed character decrease the Font IDI steps per inch adjustment and press the Save button Press the Back button to return to the runing Move Embossing page Repeat the process until the embossed and printed last character of Font IDI is aligned Esremtar GODS Tan issuance Cari Fersonalion System Hardware Serves anual Page 163 5 Adjustments Look at the LAST letter of Font 1 1 PAN Adjust Font ID1 SPI Repeat for Font 102 Font 103 Font ID4 1 Font IDI IX SPI Finished Font IX SPI 13 Repeat the same process for Font TDZ
142. te 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 Egress ance Cari SEM Hardware Serves anual Page 29 3 Preventive Maintenance 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 Firmware Download Logd Controller Encodor Printor Selected Fie TRUSTE BOTT Select firmware file then press the Download button IDSWOPSye 115 nex 2 In the list of hex files select the file that corresponds to the new revision Firmware Download Firmware Upgrade Controller Encodor Printer selects rie 3 Press the Bownload button to download the hex file to the controller The system will report Loading the firmware Please wait Egress 2000 Wan anc Cari Sm Radar Serves anual Page 30 3 Preventive Maintenance Firmware Download MAGTEK Firmware Upgrade Controller Encoder Printer lected Fie HAEC DSMCPSys 315 hex 4 Wait about 5 minu
143. tes for the firmware to finish downloading Do not power off the device 5 After the firmware update is complete the device will make sounds as the MLB resets Wait until the sounds stop and the touchscreen reports Finished loading the firmware Firmware Download Frmwaro Upgrade Contratlor Encodor Printer Sects Fe DSMCPSye S15 Finished loading the firmware Egress 30 Tan ace Cari FOTO TET Stem Hardware Serves anual Page 31 3 Preventive Maintenance 3 5 3 Update the Printer Firmware To update the printer firmware follow the steps from section 3 5 2 but select the Printer radio button and select the hex file appropriate to the revision of the image printer firmware you want to install before pressing the button prea OOO ETE Personalizar System Hardware Senice anual Page 32 3 Preventive Maintenance 3 6 Service the Hopper Module Follow these steps to service the hopper transport 1 Use the MGP Commands page see section 2 9 How to Use Maintenance Functions On the Touchscreen to move the hopper transport from the front to the rear of the device to verify the movement is smooth and there is no belt slippage 2 Only if the hopper transport rods are dirty wipe off the dirt with a soft lint free cloth 3 Check the hopper transport drive belt for signs of damage If it is damaged contact MagTek Supp
144. tes with the device s sensors It has a bi directional data connection with the embedded PC which both modules use to coordinate motor movements and sensor states as the device performs operations It is located in the front right of the device s lower deck behind the right side access door and in front of the embedded PC Figure 4 102 Main Logie Board TOP VIEW FROM RIGHT 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Open the right side access door by following the steps in section 4 3 How to Remove Re install the Side Access Doors 3 Locate the MLB behind the right side access door toward the front of the device Figure 4 103 Main Logic Board RIGHT VIEW 4 Disconnect the Ethernet cable connecting the MLB to the embedded PC Egress 2000 Wan ance Cari Sam Radar Serves anual Page 122 4 Removal and Re installation Figure 4 104 M 5 Loosen the two thumb screws securing the MLB tray to the lower deck until they pop up Do not attempt to remove them from the tray Figure 4 105 Main Logie Board Thumb Screws RIGHT VIEW 6 Use the finger holes to slowly and carefully pull the MLB out of the device and set it aside on an appropriate work surface pret 0000 Teta Cani P
145. the current setting enter the new value in the text entry box at the top right of the screen and press the E key 8 If most of the FontID2 embossed character thicknesses are less than 0 0180 increase the thickness a Select FontID2 gt CamAngleTop add 10 to the current setting enter the new value in the text entry box at the top right of the screen and press the E key b Ifthe latest tuning card was slightly concave down frowning around FontID2 leave FontID2 gt CamAngleBottom setting as it is Otherwise select FontID2 gt CamAngleBottom add 10 to the current setting enter the new value in the text entry box at the top right of the screen and press the E key 9 Press the Save button to save the new settings 10 Repeat the steps in this section until all embossed font thicknesses are between 00180 and 00190 Cari System Hardware Serves anual Page 156 5 Adjustments 54 8 Aligning Embossed Characters with Printed Characters IMPORTANT Skip section 5 4 8 if the EC2000 you are calibrating does NOT require embosser tuning EC1000 backward compatibility 5 4 8 1 About Aligning Embossed and Printed Characters When not using the foil tipping feature the EC2000 can apply coloring to embossed characters using a two step process 1 First the EC2000 prints the face s of the card with non raised ink 2 Later the EC2000 stamps the raised or indented
146. the top deck plate below the center of the hopper module see Figure 4 33 Unplug the HOME SENS and EXC HOME SENS cables from the breakout board If EXC HOME SENS is routed underneath the breakout board carefully thread it out and free it Trace the cables back to the hopper module and cut any cable ties holding them to the top deck plate Leave the cut cable ties in place to mark the mount points and to loosely hold any other cables you are not removing 20000 Teta Cani Personalizar System Hardware Senice anual Page 64 4 Removal and Re installation Figure 4 33 Hopper Module Breakout Board TOP VIEW FROM FRONT 10 Trace the hopper module s flex cable to where it plugs in to the hopper transport see Figure 4 34 Figure 4 34 Hopper Transport Flex Cable Connection FRONT RIGHT VIEW 11 Disconnect the flex cable from the hopper transport and carefully pull it free from the small pad of double sided foam tape just next to the plug see Figure 4 35 OOO Ieantlsusncs PersonalzsHon System Hardware Senice anual Page 65 4 Removal and Re installation Figure 4 35 Disconnecting the Hopper Transport Flex Cable 12 Use the 5 32 in ball end Allen wrench to remove the four screws that secure the four corners of the hopper module to the top deck plate Some screws require inserting the Allen wrench through openings in the hopper deck plate See Figure 4 3
147. to re install 15 minutes plus any sub procedures The XY transport receives cards from the image printer module and moves them to the embosser module then to the exit transport module It is located along the left side of the device 46500145 4X 133070790 Figure 4 65 Removing and Re Installing the XY Transport Module FRONT RIGHT VIEW Follow these steps to remove the XY transport module from the device 1 Prepare the device for replacing parts by following the steps in section 4 1 How to Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Disengage and lean back the top access door by following the steps in section 42 How to Remove Re install the Top Access Door up to the point where the top access door is leaning up and back behind the device 3 Move the XY transport toward the front of the device see section 2 8 How to Safely Move Transports By Hand 4 Locate the XY transport s ground cable which is connected to the deck plate behind the image printer as shown in Figure 4 66 prea 000 Ielantisusncs Cani Personalizar System Hardware Senice anual Page 88 4 Removal and Re installation Figure 4 66 XY Transport Ground Cable TOP VIEW FROM REAR 5 Use the No 2 Philips screwdriver to remove the screw and set it aside 6 Snap open the XY transport ribbon cable clamp betw
148. top calibrating the Tipper Motor Angle setting and notify Engineering Perform further adjustments by decreasing the Dwell Time setting Ifthe tipper is leaving embossed characters uncovered use the arrow buttons to increase the Tipper Motor Angle setting add 10 If you increase to the maximum value of 210 calibrating the Tipper Motor Angle setting and notify Engineering Perform further adjustments by increasing the Dwell Time setting 4 Press the Bave button to save settings and press DK close the confirmation popup window e Repeat these steps from the beginning until the Tipper Motor Angle is properly calibrated 5 8 4 Calibrate Dwell Time Dwell time is how long the tipper holds the foil on embossed characters during the tipping cycle and can be adjusted on the same page as Tipper Motor Angle A typical dwell time is 100ms Egress 30 san anc Cari Fersonaison Sam Radar Series anual Page 176 5 Adjustments If you reached maximum for the Tipper Motor Angle setting and the device is still not covering embossed characters completely increase the setting by steps of Ims until the tipper covers properly If you reached a minimum for the Tipper Motor Angle setting and the device is still overflashing decrease the Tipper Motor Time setting by steps of Ims until the tipper covers properly 5 8 5 Calibrate Foll Cool Time During the tipping cycle the hot tipper fuser presses the foil against t
149. ustments to change thickness and bending of a card To make sure the embosser is reaching that minimum character thickness follow these steps 1 Create and measure a tuning card pret 20000 Tle Cad Personalzston System Hardware Senice anual Page 153 5 Adjustments 2 embossed character thickness is between 0 017 in and 0 019 in and the card is flat skip to section 54 7 How to Fine Tune Embossed Character Height Using Software 3 Ifthe lowest FontID1 thickness you measured is less than 0 0120 in a In the ExpressCard 2000 Utility navigate to Menu gt Settings gt Edit Config to open the Eentiguration Ealing password page b Use the onscreen keypad to enter password 234587 and press the E iy c Use the onscreen keypad to enter password 7654321 and press the E key 4 Scroll through the settings list to find FontIDI CamAngleTop and FontID1 CamAngleliottom e Select FontID1 gt CamAngleTop add 10 to the current setting enter the new value in the text entry box at the top right of the screen and press the E key f Select FontID1 gt CamAngleBottom add 10 to the current setting enter the new value in the text entry box at the top right of the screen and press the E key 3 Press the Bava button to save the new settings h Repeat all steps in section 5 45 4 Ifthe highest FontIDI thickness you measured is less than 0 0170 in a Ifthe card is bent concave down frowning increase the pressur
150. ut a finger on each side of the lowest straight sides of the silver portion of the cover see Figure 4 27 Squeeze each side inward carefully and press toward the rear of the device until the base of the device captures them pert 00D ETE TETAS Cad Personalizar System Hardware Senice anual Page 59 4 Removal and Re installation Figure 4 27 Fitting the Silver Portion of the Cover FRONT VIEW 10 Bump the front of the silver portion of the cover justto the right of the card output hopper with the palm of your hand to firmly seat the cover in place 11 Make sure the silver portion of the cover is solidly seated in the slot in the base and that the darker portion of the cover is properly seated above it See Figure 4 28 for reference Figure 428 Silver Portion of Cover Properly Seated REAR LEFT V 12 Make sure the two sides of the cover roughly line up with their screw holes This will align the screw holes in the front of the cover 20000 Ielantlausncs Cad Peronalzston System Hardware Senice anual Page 60 4 Removal and Re installation 13 Use your fingers to insert the two screws that fasten the cover to the front of the device see Figure 4 22 then use the No 1 Philips screwdriver to loosely screw them into place to constrain the cover from moving left to right 14 Loosely screw in the two screws that fasten the cover to the rear plate see Figure 4 18
151. with standard safety practice 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 you have adequate lighting around the device or plan to use a flashlight Make sure you have a safe location to place removed parts and replacement parts 4 Ifthe relevant replacement procedure requires you to use the touchscreen user interface perform those steps while the device is still powered up and connected to the network 5 Power down the device 6 Disconnect the device s power cable from the AC socket outlet then disconnect the power cable and network cable from the rear of the device 7 IE necessary unlock or disconnect any security hardware from the device 8 Ifthe replacement procedure requires you to remove the device s top access door or the entire cover requires rear access to the device make sure you have adequate clearance around the device Depending on the installation location you may need to move the device to a service location Egress GODS san issuance Cari Stem Hardware Serves anual Page 43 4 Removal and Re installation 4 2 Howto Remove Re install the Top Access Door Approximate time to remove 5 minutes plus any sub procedures Approximate t
152. y sub procedures The power controller monitors the power button on the front of the device and coordinates activity between the device s embedded PC main logic board and power supply to properly power up and power down the device It is located in the bottom deck of the device and is attached along with the backplane that connects the main logic board to most of the devi toa long tray that runs along nearly the entire width of the device Figure 4 107 Power Controller and Backplane Connector LEFT VIEW To remove the power controller and backplane follow these steps the device for replacing parts by following the steps in section 4 1 How to Prepare the ice for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected 2 Open the top access door see section 2 7 How to Open the Top Access Door If you have difficulty with the clearances within the device when performing this procedure you may optionally remove the entire cover by following the steps in section 4 4 How to Remove Re install the Cover 3 Remove both side access doors by following the steps in section 4 3 How to Remove Re install the Side Access Doors 1 Pre prea OOO Ielantlsusmcs PEATE System Hardware Senice anual Page 125 4 Removal and Re installation 4 On the right side of the device pull the embedded PC out a few inches by following the
153. yu cys xune 20 Gerona Fo toch Ca rtm tnos mp Printer Utility oss ue 9 Use the on screen keypad to enter password and press the E key to launch the second password paze 10 Use the on screen keypad to enter password 688321 and press the EJ key to launch the paze 11 Select the text box below the word Command to bring up the on screen keyboard 12 Use the on screen keyboard to enter the case sensitive command Pme 1440 960 and press the Bend button This sets the distance cards will be pushed out of the printer on exit The Response box should display OK Egress GODS Wan issuance Cari POTEET System Radar Serves anual Page 170 5 Adjustments Printer Utility 14 Press the Reset Printed button and wait about 10 seconds until the printer stops making sounds prea 20000 Weta TRU Cari Peronalzston System Hardware Senice anual Page 171 5 Adjustments Printer Utility Pewter MOSK MAS ome pem m acp 5 6 3 Howto Callbrate Image Alignment EC2000 image printer s factory settings are calibrated to within 0 01 1 1007 of a reference image which is finer than can be seen by the human eye This is also the maximum resolution of the EC2000 s card design XML files Because of this MagTek does not prescribe any additional printer align

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