Magtek EXPRESSCARD 1000 Operating instructions

EXPRESSCARD 1000
INSTANT-ISSUE CARD
PERSONALIZATION SYSTEM
USER INSTALLATION AND OPERATION
MANUAL
FEBRUARY 2008
Manual Part Number: 99875351-3
REGISTERED TO ISO 9001:2000
20725 South Annalee Avenue
Carson, CA 90746
Phone: [phone] FAX: [phone]
Technical Support: [phone]
www.magtek.com

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Copyright
©
2007 - 2008
MagTek
®
, Inc.
Printed in the United States of America
Information in this document is subject to change without notice. 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.
ExpressCard 1000™is a trademark of MagTek, Inc.
MagnePrint™is a trademark of MagTek, Inc.
Windows is a registered trademark of Microsoft Corporation.
All other system names and product names are the property of their respective owners.
REVISIONS
Rev Number Date
1.01 30 July 2007
2.01 03 January 2008
3.01 29 February 2008

LIMITED WARRANTY
MagTek warrants that the products sold to Reseller pursuant to this Agreement will perform in accordance with
MagTek’s published specifications. This warranty shall be provided only for a period of ninety days from the date
of the shipment of the product from MagTek (the “Warranty Period”). This warranty shall apply only to the original
purchaser unless the buyer is authorized by MagTek to resell the products, in which event; this warranty shall apply
only to the first repurchase.
During the Warranty Period, should this product fail to conform to MagTek’s specifications, MagTek will, at its
option, repair or replace this product at no additional charge except as set forth below. Repair parts and replacement
products will be furnished on an exchange basis and will be either reconditioned or new. All replaced parts and
products become the property of MagTek. This limited warranty does not include service to repair damage to the
product resulting from accident, disaster, unreasonable use, misuse, abuse, customer’s negligence, Reseller’s
negligence, or non-MagTek modification of the product. MagTek reserves the right to examine the alleged
defective goods to determine whether the warranty is applicable.
Without limiting the generality of the foregoing, MagTek specifically disclaims any liability or warranty for goods
resold in other than MagTek’s original packages, and for goods modified, altered, or treated by customers.
Service may be obtained by delivering the product during the warranty period to MagTek (20801 S. Annalee Ave.,
Carson, CA 90746). If this product is delivered by mail or by an equivalent shipping carrier, the customer agrees to
insure the product or assume the risk of loss or damage in transit, to prepay shipping charges to the warranty service
location and to use the original shipping container or equivalent. MagTek will return the product, prepaid, via a three
(3) day shipping service. A Return Material Authorization (RMA) number must accompany all returns.
MAGTEK MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND MAGTEK DISCLAIMS ANY
WARRANTY OF ANY OTHER KIND, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
EACH PURCHASER UNDERSTANDS THAT THE MAGTEK PRODUCT IS OFFERED AS IS. IF THIS
PRODUCT DOES NOT CONFORM TO MAGTEK’S SPECIFICATIONS, THE SOLE REMEDY SHALL BE
REPAIR OR REPLACEMENT AS PROVIDED ABOVE. MAGTEK’S LIABILITY, IF ANY, TO RESELLER
OR TO RESELLER’S CUSTOMERS, SHALL IN NO EVENT EXCEED THE TOTAL AMOUNT PAID TO
MAGTEK BY RESELLER UNDER THIS AGREEMENT. IN NO EVENT WILL MAGTEK BE LIABLE TO
THE RESELLER OR THE RESELLER’S CUSTOMER FOR ANY DAMAGES, INCLUDING ANY LOST
PROFITS, LOST SAVINGS OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF
THE USE OF OR INABILITY TO USE SUCH PRODUCT, EVEN IF MAGTEK HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY.
LIMITATION ON LIABILITY
EXCEPT AS PROVIDED IN THE SECTIONS RELATING TO MAGTEK’S LIMITED WARRANTY,
MAGTEK’S LIABILITY UNDER THIS AGREEMENT IS LIMITED TO THE CONTRACT PRICE OF THE
PRODUCTS.
MAGTEK MAKES NO OTHER WARRANTIES WITH RESPECT TO THE PRODUCTS, EXPRESSED OR
IMPLIED, EXCEPT AS MAY BE STATED IN THIS AGREEMENT, AND MAGTEK DISCLAIMS ANY
IMPLIED WARRANTY, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
MAGTEK SHALL NOT BE LIABLE FOR CONTINGENT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES
TO PERSONS OR PROPERTY. MAGTEK FURTHER LIMITS ITS LIABILITY OF ANY KIND WITH
RESPECT TO THE PRODUCTS, INCLUDING ANY NEGLIGENCE ON ITS PART, TO THE CONTRACT
PRICE FOR THE GOODS.
MAGTEK’S SOLE LIABILITY AND BUYER’S EXCLUSIVE REMEDIES ARE STATED IN THIS SECTION
AND IN THE SECTION RELATING TO MAGTEK’S LIMITED WARRANTY.
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FCC WARNING STATEMENT
This equipment has been tested and found to comply with the limits for Class A digital device, pursuant
to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a residential environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation.
FCC COMPLIANCE STATEMENT
This device complies with Part 15 of the FCC Rules. Operation of this device is subject to the following
two conditions: (1) this device may not cause harmful interference. And (2) this device must accept any
interference received, including interference that may cause undesired operation.
CANADIAN DOC STATEMENT
This digital apparatus does not exceed the Class B limits for radio noise for digital apparatus set out in the
Radio Interference Regulations of the Canadian Department of Communications.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux
appareils numériques de las classe B prescrites dans le Réglement sur le brouillage radioélectrique édicté
par les ministère des Communications du Canada.
CE STANDARDS
Testing for compliance to CE and FCC requirements was performed by an independent laboratory. The
unit under test was found compliant to Class B.
US/CANADA
This product is listed per Underwriter Laboratories and 60950-1, and CSA C22.2 No. 60950-1-03.
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SAFETY
In order to insure that it maintains the safety integrity that was designed into the product and for which it
has been evaluated by the Safety Certification Agencies, compliance with all Installation Instructions and
Safety Requirements is essential.
SAFETY REQUIREMENTS
Caution: Never do any of the following:
•Use a ground adapter plug to connect equipment to a power source receptacle that lacks a ground
connection terminal.
•Attempt any maintenance function that is not specifically described in this Manual or any other
MagTek ExpressCard 1000 Manual.
•Remove any of the covers or guards that are fastened with screws. There are not operator-serviceable
areas within these covers.
•Override or “cheat” electrical or mechanical interlock devices.
•Use supplies or cleaning materials for other than their intended purposes.
•Operate the equipment if unusual noises or odors are noticed.
Consider the following before operating the ExpressCard 1000:
•Connect equipment to a properly grounded power source receptacle. If in doubt, have the receptacle
checked by a qualified electrician.
•Improper connection of the equipment grounding conductor can result in risk of electrical shock.
•Locate equipment on a solid support surface with adequate strength for the weight of the machine.
•Be careful in moving or relocating the equipment. Use the proper lifting techniques.
•Use materials and supplies specifically designed for MagTek equipment. Use of unsuitable materials
may result in poor performance and can possibly create a hazardous situation.
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TABLE OF CONTENTS
1
 INTRODUCTION..................................................................................................................................1 
1.1  COMPONENT IDENTIFICATION.................................................................................................2 
2  UNPACKING........................................................................................................................................5 
2.1  ACCESSORY ITEMS....................................................................................................................5 
3  INSTALLATION...................................................................................................................................5 
3.1  CONNECTING POWER CABLE...................................................................................................5 
3.2  CONNECTING DATA CABLE.......................................................................................................6 
3.3  LOADING RIBBON.......................................................................................................................6 
3.4  LOADING CARDS ......................................................................................................................11 
3.5  STARTUP....................................................................................................................................14 
3.6  NETWORK CONFIGURATION...................................................................................................15 
3.7  ACTIVATION...............................................................................................................................18 
4  MACHINE OPERATION ....................................................................................................................20 
4.1  CALIBRATION ............................................................................................................................20 
4.2  PRINTING A TEST CARD..........................................................................................................24 
4.3  SECURITY..................................................................................................................................25 
4.4  CHANGING DEFAULT PASSWORD .........................................................................................26 
5  MAINTENANCE.................................................................................................................................27 
5.1  PRINT HEAD...............................................................................................................................27 
5.2  CLEANING THE PLATEN AND CARD FEED ROLLER.............................................................27 
6  TROUBLESHOOTING.......................................................................................................................29 
6.1  DIAGNOSTICS............................................................................................................................29 
6.2  TECHNICAL SUPPORT .............................................................................................................29 
APPENDIX A ..............................................................................................................................................30 
A.1 SUPPLIES........................................................................................................................................30 
A.2 TECHNICAL SPECIFICATIONS......................................................................................................31 

1 Introduction
The ExpressCard 1000 (EC1000) is a desktop card production/personalization system that can fully
personalize any CR80 sized Credit/Debit/ATM/Gift cards. Allowing financial institutions the capability,
speed and convenience of instant-issuance financial cards at all branch locations.
When integrated with Magtek IntelliCat or MCAPS 3000 instant card issuance software suits, cardholders
can also be provided with the convenience and security of consumer-selected PIN capabilities. All of the
security privileges, transaction logs, card inventory, and cardholder databases can be monitored and
controlled from a central location.
The EC1000 is also equipped with a MagnePrint Reference Capture module that allows each
card’s unique MagnePrint signature to be captured and registered as it is issued to the legitimate
cardholder. This registered MagnePrint value can then be used to protect legitimate cardholders
by validating that the authentic card is being used at ATM, Teller Window, Home Banking, or
POS locations versus a counterfeit copy manufactured by criminals.
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1.1 COMPONENT IDENTIFICATION
Figure 1.1
Figure 1.2
2

Figure 1.3 (top) & Figure 1.4 (bottom)
3

Figure 1.5
15. Card Hopper One
16. Card Hopper Two
17. Card weight
18. XY Transport
19. Printer
20. Card Hoppers
21. Reject Card Bin
22. Card Exit Transport
23. Embosser
1. LCD Touch Screen
2. Card Eject Bin
3. Reset button (small pin hole)
4. Model and Serial Number
5. Windows Product Key
6. Product Identification Label
7. Secure anchor point
8. Main power switch and plug
9. Ethernet Data port
10. MSR Rail
11. Top Cover Cylindrical Lock
12. Card Access door
13. Exception Feed Slot
14. Reject Card Bin
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2 UNPACKING
When removing the EC1000 from its shipping container inspect the unit for any possible
shipping damage if damage is present contact you sales representative. Note: before you power
up the EC1000 open the top cover and remove the shipping restraints on the XY assembly
(yellow beaded ties).
2.1 ACCESSORY ITEMS
The following items should be included in your EC1000 box:
•2 Keys for the top cover
•50 additional white blank cards (p\n:96500055)
•1 printed sample card
•Stylus for monitor
•AC power cord (p\n:71100001)
•Crossover network cable (p\n:22350303)
•Cleaning card (p\n: 96700020)
•2 Card weights (p\n: 84400036)
If any of the listed items are missing contact your sales representative to obtain the missing
parts.
3 INSTALLATION
Make sure the EC100 is placed on a flat level surface (capable of supporting 85lbs.)
before you begin connecting any of the cables. If the surface is not flat and level the
machine will not function properly.
3.1 CONNECTING POWER CABLE
Attach the included power cable to the EC1000’s plug (shown below) and connect the other
end into a properly grounded wall power socket.
Figure 3.1
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3.2 CONNECTING DATA CABLE
Before connecting the Ethernet data cable to the EC1000, you must first determine if the system
will be a standalone unit (meaning it will be connected to a single computer) or connected to the
local area network. If the EC1000 will be a standalone unit, use the provided crossover cable to
connect the computer’s Network Interface Card (NIC) to the EC1000’s data port (shown below).
Figure 3.2
However, if the EC1000 will be connected to the local network plug a standard Ethernet patch
cable will need to be used instead of the cross over cable.
Note: Although the crossover cables and Ethernet cables look alike they are wired
differently which means using the wrong cable will prevent a data connection.
3.3 LOADING RIBBON
Follow these steps to load ribbon into the Printer:
1) Remove the ribbon and cleaning roller from its packaging. Do not touch the colored
portion of the ribbon. Oil or dirt from the hands can impair print quality.
Figure 3.3
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2) The supply end of the ribbon is the side with the fresh, unused ribbon. Used ribbon will
be taken-up at the other end. Note the gray cores must be present on the supplied ribbon
side in order for the Printer to print properly.
Figure 3.4
3) Open the Top Cover of the EC1000 by inserting and turning the key. Gently grasping the
top handles of the Cover and lifting upward. The Cover will lift up and fold in half
exposing the printer beneath. (A user password will also be needed to open electronic
locks on the cover, refer to section 4.3 for the unlocking procedure)
Figure 3.5
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4) Open the Print head assembly by gently pulling up on the assembly’s release tab and
lifting upward. This will allow the assembly to swing completely open.
Figure 3.6
Figure 3.7
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5) Place the supply end of the ribbon in between the green and gray ribbon drive hubs
located on the right-hand side of the printer’s interior (match the green ring of the ribbon
to the green ring of the drive hub). Make certain that the ribbon is fed from underneath
the ribbon roll. Hint: The ribbon drive hub is on the right side of the printer, as you are
looking into the EC1000 from the front side. Use the end of the ribbon supply core to
push in this ribbon drive hub when inserting the ribbon. Place the take-up end of the
ribbon roll in between the two gray ribbon drive hubs located on the left-hand side of the
printer’s interior. Load the ribbon take-up end just as you loaded the ribbon supply end.
Figure 3.8
6) When loaded properly, the ribbon should feed underneath both ends of the ribbon roll.
Grasp the release tab and gently lower the print head assembly to close it.
Figure 3.9
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7) Every time the ribbon is replaced the card cleaning cartridge must also be replace. To
replace the card cleaning cartridge lift the cleaning assembly out of the printer as shown.
Figure 3.10
8) Once the assembly has been removed replace the card cleaning roller and remove the
protective tape on the new roller. Then reinstall the card cleaning assembly into the
printer.
Figure 3.11
9) Close the EC1000’s top cover. When you start to print, the ribbon drive hubs will
automatically engage the notches on both cores of the ribbon roll. Note: If the ribbon
type is not automatically recognized the printer should be calibrated, refer to
section 4.1 for calibration instructions.
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3.4 LOADING CARDS
The EC1000 prints onto standard CR-80 size cards (3.375L x 2.125W x .030 / 86mmL x
54mmW x .75mm), which have a clean, level, polished PVC surface.
•Although the Printer is equipped with card cleaning Rollers, it is very important to
always print onto cards designed for direct-to-card, thermal printing. (Note: For this
reason, a special card stock is available which is specifically designed for printing with
the Printer.)
•This card stock provides a level, polished PVC surface free of fingerprints, dust and any
other types of embedded contaminants.
•In addition, this card stock is packaged and shipped in dust-free plastic bags. To order
compatible card stock, contact the sales representative or see appendix for ordering
supplies.
Caution: Never run cards with a contaminated, dull or uneven surface through the
Printer. Printing onto such cards will ultimately lead to poor print quality and will greatly reduce
the life of the Print head. In addition, always store the card stock in its original packaging or in a
clean, dust-free environment. Do not print onto cards which have been dropped or soiled. Print
heads damaged by contaminated or poor quality cards will automatically void the print
head’s factory warranty.
The EC1000 holds a maximum of 100 CR-80 size cards in each Card Input Hopper (refer to fig.
1.4). It will automatically feed each card off the bottom of the stack unless a single card is placed
into the manual feed slot. To load the cards into the printer, refer to the following steps:
1) Open the EC1000 card door cover via the touch screen (refer to section 4.4 for unlocking
procedure) once electronic locks open you will have ten seconds to open door before
locks reengage.
2) Remove a stack of 100 or fewer cards from the card packaging. Do not touch the area of
the cards on which you intend to print. Oil or dirt from the hands can impair print quality.
Handle cards only along the edges.
3) Load the stack of cards into the EC1000 card input tray and pushing the stacks all the
way to the back of the card input hoppers. Always load cards with the top or primary
print side facing up. If inserting cards with a magnetic stripe be sure the magnetic stripe
is positioned downward and that the stripe is oriented toward the rear of the EC1000. If
inserting smart cards, be sure the end of the card containing the smart card chip is
inserted first.
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Figure 3.12 Figure 3.13
4) Once the cards have been inserted, remove the top card and throw it away if you suspect
it has been contaminated with oil from the fingertips.
5) Before the card door is closed make sure that you place the card weight with the arrow
facing up on top of the card stack to insure proper feed by the printer. Note: if the card
weight is not placed on the card stock properly (arrow side up and facing inward) it
will create jams.
Figure 3.14
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Additional Notes:
•If the card weight is not placed on the card stock properly (arrow side up and
facing inward) there will be card jams.
•Check for static build up between cards. Occasionally, a static charge will build
up between the surfaces of two or more cards causing them to stick together.
•Reduce or eliminate this static charge by separating the cards manually before
placing them in the input Hopper.
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3.5 STARTUP
Powering-up the EC1000 is a very simple process all you need to do is located at the main
power switch at the rear of the machine and turn the switch to the on position. Placing the
switch in this position will initialize the hardware and startup the computer; the whole
process will take about a minute. Once the computer has completely booted it will display the
image below and be ready for use.
To shut down the EC1000 simply press the menu button on the ready screen and select the
shut down button on the screen as shown below.
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