Magtek ExpressCard 1000 Operating instructions

EXPRESSCARD 1000

INSTANT-ISSUE CARD

PERSONALIZATION SYSTEM

USER INSTALLATION AND OPERATION

MANUAL

JANUARY 2011

Manual Part Number: 99875351-13

REGISTERED TO ISO 9001:2008

1710 Apollo Court

Seal Beach, CA 90740

Phone: (562) 546-6400

Technical Support: (888) 624-8350

www.magtek.com

ii

Copyright



2006 – 2011

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 Notes

1.01

30 Jul 2007

Initial Release

2.01

3 Jan 2008

Per ECN: 53648

3.01

29 Feb 2008

Per ECN: 53721

4.01

13 May 2008

Per ECN: 53812

5.01

8 Jul 2008

Per ECN: 53858

6.01

11 Aug 2008

Per ECN: 53919

7.01 2 Apr 2009

Per ECN: 54210 and Print head

maintenance schedule updated.

7.02 21 Apr 2009

Updated sections 2.1, 6.1,

Appendix A.

8.01 29 Oct 2009

Updated screen shots, refined

embosser alignment section,

added maintenance section,

added key loading & queuing as

Appendix B

9.01 13 Jan 2010

Section 7.3 added, tools added to

page 6

10.01 24 Feb 2010

Limited Warranty and Software

Agreement Updated

11.01 4 April 2010 Maintenance schedule updated

12.01 1 June 2010 Updated Security Policy

13.01 5 Jan 2011

Changed cleaning procedure

section 6.2

iii

Registered to ISO 9001:2008

MagTek, Inc. I 1710 Apollo Court I Seal Beach, CA 90740

t 562-546-6500 I f 562-546-6301 I www.magtek.com

Limited Warranty

MagTek warrants that the products sold to Customer pursuant to this Agreement will perform in accordance with

MagTek’s published specifications. This warranty shall be provided for a period of one year 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. Customer may extend the Warranty Period and the warranty contained herein

by purchasing at the time of initial purchase the Extended Warranty as set forth on Schedule A.

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, Customer’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 for all products except The ExpressCard 1000 may be obtained by delivering the product during the

warranty period to MagTek (1701 Apollo Court, Seal Beach, CA 90740). 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.

On-Site service for The ExpressCard 1000 may be obtained per the terms and conditions of

The ExpressCard

1000 On-Site Service Agreement (OSSA).

If an OSSA has not been executed, Depot Service may be obtained

by delivering the product to MagTek (1701 Apollo Court, Seal Beach, CA 90740). The customer agrees to

insure the product or assume the risk of loss or damage in transit, to prepay shipping charges to the depot

service location and to use the original shipping container. If the original shipping container is not available,

MagTek will ship one and charge the customer the current published price plus shipping costs. 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 CUSTOMER OR

TO RESELLER’S CUSTOMERS, SHALL IN NO EVENT EXCEED THE TOTAL AMOUNT PAID TO MAGTEK

BY CUSTOMER UNDER THIS AGREEMENT. IN NO EVENT WILL MAGTEK BE LIABLE TO THE

CUSTOMER 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.

iv

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.

v

Registered to ISO 9001:2008

MagTek, Inc. I 1710 Apollo Court I Seal Beach, CA 90740

t 562-546-6500 I f 562-546-6301 I www.magtek.com

INTELLICAT

®

SOFTWARE SUITE AND INTELLICAT

CUSTOM INTERFACE LICENSE AND MAINTENANCE AGREEMENT

IMPORTANT: YOU SHOULD CAREFULLY READ ALL OF THE TERMS, CONDITIONS AND RESTRICTIONS

OF THIS LICENSE AGREEMENT BEFORE INSTALLING THE SOFTWARE PACKAGE. YOUR

INSTALLATION OF THE SOFTWARE PACKAGE PRESUMES YOUR ACCEPTANCE OF THE TERMS,

CONDITIONS, AND RESTRICTIONS CONTAINED IN THIS AGREEMENT. IF YOU DO NOT AGREE WITH

THESE TERMS, CONDITIONS, AND RESTRICTIONS, PROMPTLY RETURN THE SOFTWARE PACKAGE

AND ASSOCIATED DOCUMENTATION TO ABOVE ADDRESS ATTENTION: CUSTOMER SUPPORT.

TERMS, CONDITIONS AND RESTRICTIONS

MagTek, Incorporated (the “Licensor”) owns and has the right to distribute the described software and

documentation, collectively referred to as the “Software”.

LICENSE:

In consideration for the license fee Licensor grants you (the “Licensee”) the right to use the Software in

conjunction with MagTek Motorized IntelliCoder

®

, ExpressCard 1000 and IntelliPIN

®

products, and other

MagTek approved Card Personalization Devices here after referred to as “CPD”. A separate Software License

fee and a separate Software Maintenance fee is required for each CPD Licensee purchased. By accepting this

Software License the Licensee agrees to pay an initial License Fee and an annual Software Maintenance fee

described in Schedule A. The annual Software Maintenance fee will be automatically billed to the Licensee and

will afford the Licensee on-going Software support and any future upgrades without additional charges.

LICENSEE MAY NOT COPY, MODIFY OR TRANSFER THE SOFTWARE IN WHOLE OR IN PART EXCEPT

AS EXPRESSLY PROVIDED IN THIS AGREEMENT. Licensee may not decompile, disassemble or in any other

manner attempt to reverse engineer the Software. Licensee shall not tamper with, bypass or alter any security

features of the software or attempt to do so.

TRANSFER:

Licensee may not transfer the Software or license to the Software to another party without prior written

authorization of the Licensor. If Licensee transfers the Software without authorization, all rights granted under

this Agreement are automatically terminated.

COPYRIGHT:

The Software is copyrighted. Licensee may not copy the Software except for archival purposes or to load for

execution purposes. All other copies of the Software are in violation of this Agreement.

TERM:

This Agreement is in effect as long as Licensee continues the use of the Software. The Licensor also reserves

the right to terminate this Agreement if Licensee fails to comply with any of the terms, conditions or restrictions

contained herein. Should Licensor terminate this Agreement due to Licensee's failure to comply, Licensee

agrees to return the Software to Licensor. Receipt of a returned Software by the Licensor shall mark the

termination of future billing for any applicable Software maintenance charges, but shall not terminate any

obligation on behalf of Licensee for Software maintenance charges due and payable.

vi

FCC WARNING STATEMENT

This equipment has been tested and was found to comply with the limits for a 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 commercial 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 with radio communications. Operation

of this equipment in a residential area is likely to cause harmful interference in which case the user

will be required to correct the interference at his own expense.

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 A limits for radio noise from 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 la classe A prescrites dans le Réglement sur le brouillage radioélectrique

édicté par le ministère des Communications du Canada.

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numériqué de la classe A est conformé à la norme NMB-003 du Canada.

CE STANDARDS

Testing for compliance with CE requirements was performed by an independent laboratory. The unit

under test was found compliant with standards established for Class A devices.

UL/CSA

This product is recognized per Underwriter Laboratories and Canadian Underwriter Laboratories

1950.

RoHS STATEMENT

When ordered as RoHS compliant, this product meets the Electrical and Electronic Equipment (EEE)

Reduction of Hazardous Substances (RoHS) European Directive 2002/95/EC. The marking is clearly

recognizable, either as written words like “Pb-free”, “lead-free”, or as another clear symbol ( ).

vii

ExpressCard 1000 Security Policy

MagTek is a leading provider of electronic transaction security. As a manufacturer of card personalization

equipment, MagTek has the responsibility to secure the manufacturing, delivery, implementation and ongoing

use of its card personalization devices.

The ExpressCard 1000 makes debit, credit, ATM and gift cards immediately. All of these plastic cards are

considered legal currency that can be used throughout the world. In cooperation with the Card Organizations

and the US Secret Service, MagTek has a responsibility to the industry and the public at large to ensure that its

machines are only used by responsible, authorized parties and to minimize any consequential damage that may

result from the theft or unauthorized use of the product. MagTek recognizes the threat posed by organized

criminal enterprises, which exploit financial transaction cards for the purpose of Identity Theft and Payment

Card Fraud domestically and internationally.

Credit card service bureaus have traditionally provided card personalization services from controlled, secure

and restricted environments. Consider that the ExpressCard 1000 is a portable service bureau, requiring

equivalent security measures. Guidelines established by Visa and MasterCard, require that card personalization

devices must ship in a deactivated state requiring the financial institution to work in concert with the

manufacturer to enable the machine for card production. ExpressCard 1000 uses a Digital Certificate Device

Authentication method that enables the machine for first use and provides ongoing controlled activation to

ensure that if the device falls into the hands of an unauthorized user, its potential for damage to the payment

industry is minimized. Use of the ExpressCard 1000 Digital Certificate Authentication Method, reduces the card

issuer’s exposure to fraud and limits its liability. This service, provided without charge by MagTek, does not

view, gather or store any proprietary user information or cardholder data. It is a responsible approach to secure,

distributed card issuance. There are two methods of enabling an ExpressCard 1000.

In the first method, the ExpressCard 1000 generates an encrypted challenge and communicates directly to

MagTek’s Certificate Authority (CA) using an SSL connection. Once the ExpressCard 1000 and MagTek’s CA

have been mutually authenticated, a new digital certificate is transmitted to the ExpressCard 1000, enabling the

machine to operate for a predetermined period of time.

The second method utilizes the same process. However, a proxy server on the financial institution’s network

provides the channel by which the request for and the delivery of the Digital Certificate is provisioned. Use of

the proxy server affords financial institutions the opportunity to monitor the traffic to and from MagTek’s CA

and avoids the need for direct communication with the ExpressCard 1000.

In view of the growing need for stronger security to combat criminal enterprises that have become more

creative and brazen in their attempt to terrorize the payment infrastructure, it is the responsibility of

manufacturers, the financial institutions and card associations to create and implement secure infrastructure to

combat the motivated, highly skilled and well funded criminals. In addition to honoring card association rules,

MagTek as a member of PCI DSS, has made a commitment to protect the interests of the industry it serves, and

has taken a strong leadership role in this security effort.

viii

ix

SAFETY

In order to ensure the preservation of safety and integrity features that were designed into this 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 no 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.

x

TABLE OF CONTENTS

1

INTRODUCTION .................................................................................................................................. 1

1.1 COMPONENT IDENTIFICATION ................................................................................................. 2

2 UNPACKING AND PACKING ............................................................................................................. 5

2.1 ACCESSORY ITEMS .................................................................................................................... 6

2.2 TRANSPORTATION OF UNIT ...................................................................................................... 7

3 INSTALLATION ................................................................................................................................... 9

3.1 CONNECTING CABLES ............................................................................................................... 9

3.2 LOADING RIBBON ..................................................................................................................... 11

3.3 CARD CLEANING CARTRIDGE REPLACEMENT .................................................................... 15

3.4 LOADING CARDS ...................................................................................................................... 18

3.5 STARTUP .................................................................................................................................... 21

3.6 NETWORK CONFIGURATION ................................................................................................... 24

3.7 ENABLE/DISABLE ...................................................................................................................... 28

4 MACHINE OPERATION .................................................................................................................... 31

4.1 CALIBRATION ............................................................................................................................ 31

4.2 PRINTING A TEST CARD .......................................................................................................... 36

4.3 SECURITY .................................................................................................................................. 37

4.3.1 Securing the ExpressCard Chassis .................................................................................... 37

4.3.2 Enabling Case and Door Access ........................................................................................ 38

4.3.3 Opening the Top Cover and Card Access Door ................................................................. 39

4.3.4 Changing Default Passwords .............................................................................................. 41

4.4 HELP SCREEN ........................................................................................................................... 43

5 ADJUSTMENT ................................................................................................................................... 47

5.1 ADJUSTMENT OF EMBOSSED CHARACTER POSITION ....................................................... 47

5.2 ADJUSTMENT OF EMBOSSED CHARACTER SPACING ........................................................ 51

5.3 HOW TO ALIGN THE EMBOSSED CHARACTERS AND PRINTED IMAGE ............................ 53

5.4 ENABLE/DISABLE PRINTER HOPPER SENSOR .................................................................... 55

6 MAINTENANCE ................................................................................................................................. 57

6.1 PRINT HEAD............................................................................................................................... 57

6.2 CLEANING THE PLATEN AND CARD FEED ROLLER............................................................. 59

6.3 CLEANING THE PRINTER ENCODER ...................................................................................... 66

7 TROUBLESHOOTING ....................................................................................................................... 70

7.1 DIAGNOSTICS............................................................................................................................ 70

7.1.1 Loading ................................................................................................................................ 70

7.1.2 Communication ................................................................................................................... 72

7.1.3 Printing ................................................................................................................................ 72

7.2 COMMON ERRORS ................................................................................................................... 72

7.3 REMOVING STUCK CARDS ...................................................................................................... 77

APPENDIX A .............................................................................................................................................. 84

A.1 SUPPLIES ................................................................................................................................... 84

A.2 TECHNICAL SPECIFICATIONS ................................................................................................. 85

APPENDIX B .............................................................................................................................................. 86

INTRODUCTION TO KEY LOADING ..................................................................................................... 86

Support Key Schemes ........................................................................................................................ 86

xi

Key Loading Design ........................................................................................................................... 86

KEY LOADING........................................................................................................................................ 87

KMC, IMK, and Data key as Components ......................................................................................... 87

KMC, IMK, and Data key as Encrypted .............................................................................................. 88

SESSION KEY LOADING ...................................................................................................................... 90

KMC Key Loading............................................................................................................................... 92

IMK Key Loading ................................................................................................................................ 94

Encrypted KMC Key Loading ............................................................................................................. 96

Encrypted IMK Key Loading ............................................................................................................. 100

Data Key Loading ............................................................................................................................. 104

Encrypted Data Key Loading ............................................................................................................ 106

QUEUEING ........................................................................................................................................... 110

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This Page is Intentionally Blank

Installation and Operation Manual

Page 1

1 Introduction

The ExpressCard 1000 (EC1000) is a desktop card production/personalization system that can fully

personalize any CR80 sized Credit/Debit/ATM/Gift card, allowing financial institutions the capability,

speed, and convenience of instant-issuance of financial cards at all branch locations.

When integrated with MagTek’s IntelliCat or MCAPS 3000 instant card issuance software suites

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 card being used at an ATM, Teller Window, Home Banking, or POS

location is authentic, not a counterfeit copy manufactured by criminals.

Section 1: Introduction

Page 2

1.1 COMPONENT IDENTIFICATION

Figure 1.1

Figure 1.2

Installation and Operation Manual

Page 3

Figure 1.3

Figure 1.4

Section 1: Introduction

Page 4

Figure 1.5

1. LCD Touch Screen

2. Card Eject Bin

3. Reset button (small pin hole)

4. Serial Number

5. Windows Product Key

6. Product Identification Tag

7. Secure anchor point

8. Main power switch and plug

9. Ethernet Data port

10. Rear Cooling Fans

11. Manual Swipe Rail (MSR)

12. Cylindrical Lock (Top Cover)

13. Card Access Door

14. Exception Feed Slot

15. Card Hopper Number 1

16. Card Hopper Number 2

17. Card Weight

18. Card Reject Bin (side view)

19. XY Transport

20. Printer

21. Card Hoppers

22. Embosser

23. Card Exit Transport

24. Card Reject Bin (top view)

Installation and Operation Manual

Page 5

2 UNPACKING AND PACKING

After removing the EC1000 from its shipping container, inspect the unit for any possible

shipping damage; if damage is present, contact your sales representative.

Note: Before powering up the ExpressCard, open the top cover and remove the yellow beaded

tie (shown below) that secures the XY assembly during shipping.

Figure 2.1

Section 2: Unpacking and Packing

Page 6

2.1 ACCESSORY ITEMS

The following items should be included in the ExpressCard accessory box shown in figure 2.2:

• 2 Keys for the top cover

• 1 printed sample card

• 50 additional white blank cards (p\n: 96500055)

• Stylus for monitor

• AC power cord (p\n: 33070518)

• Crossover network cable (p\n: 22350303)

• 13 Printer cleaning cards (p\n: 96700020)

• 13 Encoder cleaning cards (p\n: 96700004)

• 2 Card weights (p\n: 84400036)

• Straight Pick tool (p\n: 96900813) – not shown

• 90° Pick tool (p\n: 96900814) – not shown

• Hemostat pliers (p\n: 96900816) – not shown

Note: If any of the listed items are missing, contact your sales representative to obtain the

missing parts.

Figure 2.2

Installation and Operation Manual

Page 7

2.2 TRANSPORTATION OF UNIT

When and if the EC1000 is transported to an alternative location(s), the following steps must be

taken to prevent damage to the unit:

1. Remove all blank cards and weights from the card hoppers.

2. Remove the printer ribbon.

3. Remove cards from the Reject Bin.

4. Secure the XY assembly using the yellow beaded tie shipped with the machine or some

other similar device.

5. Transport the EC1000 in the appropriate box and with proper packing foam.

Section 2: Unpacking and Packing

Page 8

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Magtek ExpressCard 1000 Operating instructions

Magtek ExpressCard 1000 Operating instructions

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