ExpressCard 2000 Instant Issuance Card Personalization System Tipper Heater Replacement Procedure June 2014 Manual Part Number: 99875692-1.01 REGISTERED TO ISO 9001:2008 MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: (562) 546-6400 I Technical Support: (888) 624-8350 www.magtek.
Copyright © 2006 - 2014 MagTek, Inc. Printed in the United States of America Information in this publication is subject to change without notice and may contain technical inaccuracies or graphical discrepancies. Changes or improvements made to this product will be updated in the next publication release. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of MagTek, Inc.
SAFETY This product has been evaluated by multiple safety certification agencies, including Underwriters Laboratories (UL) and the United States Federal Communications Commission (FCC Class A and Class B), and is designed to protect both the user and the device. This document is written specifically to work in conjunction with these safety and integrity features to protect the user and the device.
1 - Table of Contents Table of Contents Table of Contents ............................................................................................................................... 4 1 Required Tools, Materials, and Documents ........................................................................... 5 1.1 Required Tools ..................................................................................................................... 5 1.2 Suggested Tools .......................................
1 - Required Tools, Materials, and Documents 1 Required Tools, Materials, and Documents 1.1 Required Tools Part Number Quantity Description 33011008 1 ea. ASM TOOL KIT,FIELD SERVICE,EC2000 N/A 1 ea. Small diagonal side cutters 1.2 Suggested Tools Part Number N/A 1.3 Quantity 1 ea. Description Flashlight Required Materials Part Number 33070911 1.4 Quantity 1 ea. Description ASM TIPPER HEATER REPLACEMENT KIT,EC2000 Suggested Materials Part Number Quantity Description 33011009 1 ea.
2 - Introduction 2 Introduction This procedure describes how to replace the tipper heater in the ExpressCard 2000 (EC2000), and is based on content in 99875607 ExpressCard 2000 Hardware Service Manual. It assumes the reader is familiar with basic operation of the ExpressCard 2000’s user and maintenance functions, so many of the cross-references to deeper “how-to” procedures from that manual have been removed for brevity.
3 - Tipper Heater Replacement Procedure 3 Tipper Heater Replacement Procedure 3.1 Prepare the Device Prepare the device for preventive maintenance by following these steps: 1) Offer the customer the opportunity to remove any proprietary or security-sensitive consumables from the device, including card stock, image printer ribbons, indent cartridges, and tipper foils. Some consumables contain negative imprints of cardholder data and must be handled securely.
3 - Tipper Heater Replacement Procedure Figure 3-1 - Tipper Heater Cable (TOP VIEW FROM FRONT) 5) Cut the plastic cable tie that holds the tipper heater cable connectors to the left side of the tipper module. If the cable does not have connectors like those shown in Figure 3-2, you may be working on an older device; contact MagTek for alternate instructions. Figure 3-2 - Tipper Heater Cable Tie (TOP LEFT VIEW) 6) Unplug the tipper heater cable.
3 - Tipper Heater Replacement Procedure Figure 3-3 - Tipper Heater Plug (FRONT RIGHT VIEW) 7) Use the 3/32” Allen wrench to remove the two screws that secure the tipper sensor to the tipper housing, and set them aside. Figure 3-4 - Tipper Sensor Screws (FRONT RIGHT VIEW) 8) Carefully pull the tipper sensor out of the right side of the tipper housing, and move it out of the way by looping it up and over the top of the tipper module.
3 - Tipper Heater Replacement Procedure Figure 3-5 - Removing and Re-installing the Tipper Sensor (FRONT RIGHT VIEW) 9) Use the 1/8” L-handle Allen wrench to remove the two spring-loaded posts that hold the tipper heater in the tipper module, and set them aside. Figure 3-6 - Supporting the Tipper Heater While Removing / Tightening (RIGHT VIEW) 10) Slide the tipper heater out the right side of the tipper.
3 - Tipper Heater Replacement Procedure Figure 3-7 - Removing / Re-inserting the Tipper Heater (TOP VIEW FROM FRONT) 11) Determine the number of cards the tipper heater has produced, and record the number. Set the tipper heater aside to return to MagTek for recycling. To re-install the tipper heater, follow these steps: 1) Orient the tipper heater with the flat side down and the cables coming off to the right (Figure 3-7). 2) Run the cable out the front of the tipper as shown in Figure 3-1 and Figure 3-4.
3 - Tipper Heater Replacement Procedure 5) Insert the left spring-loaded post, move the tipper heater around until it lines up, and use the 1/8” Lhandle Allen wrench to tighten it. 6) Tighten the right spring-loaded post. 7) Re-insert the tipper sensor into its slot (see Figure 3-5) and hold it in place. 8) Use the 3/32” Allen wrench to insert and tighten the two screws that hold the tipper sensor (see Figure 3-4).
