Datacard CR500 Instant Issuance System

Transcription

1 Datacard CR500 Instant Issuance System Installation and User Guide August 2013 Part No , Rev. E

2 Notice Please do not attempt to operate or repair this equipment without adequate training. Any use, operation or repair you perform that is not in accordance with the information contained in this documentation is at your own risk. These products conform to regulatory requirements as specified in North America, Europe, and Asia. Refer to Compliance Statements on page iii for more information. Trademark Acknowledgments Proprietary Notice Datacard is a registered trademark and service mark of DataCard Corporation in the United States and/or other countries. CR500 is a trademark of DataCard Corporation in the United States and/or other countries. Visa is a registered trademark of Visa Inc. All other trademarks are the property of their respective owners. Names and logos on sample cards are fictitious. Any similarity to actual names, trademarks, or trade names in coincidental. The design and information contained in these materials are protected by US and international copyright laws. This product includes software developed for the OpenSSL Project for use in the OpenSSL Toolkit. ( It also includes cryptographic software written by Eric Young (eay@cryptsoft.com) and software written by Tim Hudson (tjh@cryptsoft.com). Datacard Group Bren Road West Minnetonka, MN Phone: Fax: , 2013 DataCard Corporation. All rights reserved. ii

3 Compliance Statements Liability Statement The WARNING and CAUTION labels have been placed on the equipment for your safety. Please do not attempt to operate or repair this equipment without adequate training. Any use, operation or repair in contravention of this document is at your own risk. Safety All Datacard products are built to strict safety specifications in accordance with CSA/ UL requirements and the Low Voltage Directive 2006/95/EC. Therefore, safety issues pertaining to operation and repair of Datacard equipment are primarily environmental and human interface. The following basic safety tips are given to ensure safe installation, operation and maintenance of Datacard equipment. Connect equipment to a grounded power source. Do not defeat or bypass the ground lead. Place the equipment on a stable surface (table) and ensure floors in the work area are dry and non slip. Know the location of equipment branch circuit interrupters or circuit breakers and how to turn them on and off in case of emergency. Know the location of fire extinguishers and how to use them. ABC type extinguishers may be used on electrical fires. Know local procedures for first aid and emergency assistance at the customer facility. Use adequate lighting at the equipment location. Maintain the recommended temperature and humidity range in the equipment area. iii

4 Regulatory Compliance Notice for USA (FCC notice) Notice for Canada Notice for Europe This equipment has been tested and found to comply with the limits for Class A computing devices, 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. If this equipment is not installed and used in accordance with this instruction manual, it may cause harmful interference to 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 their own expense. Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. This Device complies with Industry Canada License exempt RSS standard(s). Operation is subject to the following two conditions: 1) this device may not cause interference, and 2) this device must accept any interference, including interference that may cause undesired operation of the device. Cet appareil est conforme avec Industrie Canada RSS standard exemptes de licence(s). Son fonctionnement est soumis aux deux conditions suivantes: 1) ce dispositif ne peut causer des interférences, et 2) cet appareil doit accepter toute interférence, y compris les interférences qui peuvent causer un mauvais fonctionnement du dispositif. We hereby certify that this printer complies with EMC Directive2004/108/EC, R&TTE Directive 1999/5/EC, and the EU RoHS Directive EU Directive 2011/65/EC. This printer conforms to Class A of EN and to EN Operation of this equipment in a residential environment may possibly cause interference. In the event of interference, the users, at their own expense, will be required to take whatever measures are necessary to correct the problem. Notice for China (Simplified Chinese) 为 级产 环 该产 线 这 对 iv

5 Notice for Taiwan (Traditional Chinese) Notice for Japan Japanese Voluntary Control Council for Interference (VCCI) class A statement Korea Communications Commission (KCC) statement California Proposition 65 Compliance WARNING: This product contains chemicals, including lead, known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. v

6 Revision Log CR500 Instant Issuance System Installation and User Guide Revision Date Description of Changes A May 2012 First release of manual. B July 2012 Updated with new touch screen layout. C August 2012 Updated with new touch screen and information. D Sept 2012 Updated with maintenance information. E August 2013 Updated with new error messages and printer manager information. vi

7 Table of Contents Chapter 1: Introduction 1 About This Manual 2 Intended Audience 2 Who to Call for Assistance 2 Chapter 2: About the Printer 3 About the Printer 4 Unpack the CR500 Printer 5 The Exterior of the CR500 Printer 8 Inside the Printer 9 Inside the Print Unit 9 Inside the Security Enclosure 10 The Back of the Printer 10 Options in the Printer 11 Chapter 3: Installation Requirements 13 Site Guidelines 14 Operating Environment 14 Ventilation Clearance 15 Printer Guidelines 15 Physical Security 16 Network Connection 17 Network Security 17 Use Datacard CardWizard 17 Chapter 4: Preparing a Secure Printer 19 Security at Setup 20 Locking and Unlocking the Security Enclosure 20 Unlock the Printer Using the Key 20 Lock the Printer Using the Key 21 Unlock the Printer Using Authentication 22 Lock the Printer After Using Authentication to Unlock the Printer 23 Load Cards 24 Load Ink Ribbon and Retransfer Film 26 Load Ink Ribbon 26 Load Retransfer Film 28 Chapter 5: Installing the Printer 33 Use the Bolt-Down Feature 34 Install the Concealed Card Stacker 35 Connect the Power Cords 36 Connect the Data Cable 37 Power On 37 Power On the Printer 38 Power Off the Printer 39 vii

8 Network Setup 40 Retrieve the Printer IP Address 40 Set a Static IP Address (Optional) 42 Activate the Printer 46 Set Up Network Access 49 Open Printer Manager 49 Verify Network Communication 51 Print a Test Card 51 Additional Setup Tasks 53 CardWizard Setup 53 Chapter 6: Using the Printer 55 Initialize Supplies 56 Print Cards 56 Tips for Printing Cards 56 Print Cards From CardWizard 57 Print Cards Using the Exception Card Slide 57 The Printer Touch Screen 58 User Button and Light 58 Down Arrow, Up Arrow, and Enter Keys 59 Ribbon Light 59 Card Light 60 Supplies Status Light 60 The Touch Screen LCD Menu System 60 LCD Menus 61 Card Counts 62 Messages and Conditions 62 The Print Unit Front Panel 63 Connection and Lock Symbols 64 Keys 64 Speaker 65 The Print Unit Front Panel Menu System 66 Use the Print Unit Menus 71 Apply a Second Retransfer Layer 71 Chapter 7: Taking Care of Your Printer 77 Remove Rejected Cards 78 Cleaning Schedule for Printer 79 Supplies Required 80 Clean the Printer 80 Cleaning Kit 80 Clean the Card Cleaning Rollers and Cleaning Unit 80 Clean the Multicard Hopper 83 Clean the Print Unit 84 Clean the Magnetic Stripe Head 88 viii

9 Clean the Thermal Printhead 91 Clean the Print Unit Fan Filter 92 Prepare the Printer for Transport 93 Disable Printing 93 Prepare and Package the Printer 96 Package the Printer 97 Chapter 8: Messages and Error Recovery 99 Touch Screen Messages 100 Messages on the Printer 100 Other Messages 100 Quick Link to a Message 101 Print Unit Roller Layout 123 Printer Error Recovery 124 Multicard Hopper Jam 124 Print Unit Hopper Jam 125 Transfer Jam 126 Turnover Jam 128 Retransfer Jam 130 Mend a Broken Ink Ribbon or Retransfer Film 132 Chapter 9: Supplies 135 Storage Environment for Supplies 136 Ink Ribbon and Retransfer Film 137 Ink Ribbon 137 Retransfer Film 137 Cards 138 Card Size 138 Card Material 138 Cleaning Supplies 139 Replacement Parts 139 Chapter 10: Using Printer Manager 141 Start and Stop Printer Manager 142 Start Printer Manager 142 Stop Printer Manager 143 Printer Manager Settings 144 Status Menu 145 Printer Setting Menu 147 Communication 150 ActivityLog 151 ActivityLog Example 152 Behavior 153 FrontPanel 154 Print Settings 155 Pick Settings 160 MagStripeGeneral 161 ix

10 Troubleshooting Menu 162 Test Card 163 Maintenance Menu 165 Printer Manager Updates 165 Appendix A: Printer Specification A-1 General Printer Specifications A-2 Operating Environment Conditions A-2 Storage Environment Conditions A-2 Appendix B: Magnetic Stripe Encoding B-1 Inline Encoding B-2 Formatting Magnetic Stripe Data B-2 ISO Character Code Table B-3 7-bit JIS Type II Character Set B-4 x

11 Chapter 1: Introduction This chapter introduces the printer and the documentation and support provided with it. About This Manual on page 2 Intended Audience on page 2 Who to Call for Assistance on page 2 CR500 Instant Issuance System Installation and User Guide Page 1

12 About This Manual This manual provides detailed information about the Datacard CR500 card printer. Other manuals included with the system are: Quick Install Guide Packing List Intended Audience This manual provides information for: The site manager responsible for setting up the CR500 printer and the system of which the printer is a part. The staff, such as customer service representatives, who use the printer at the issuance site. The central office technical professionals who set up and maintain card printing for issuance sites. Who to Call for Assistance If you work with a Datacard authorized dealer, distributor, or value added reseller, contact that entity for assistance. A value added reseller provides the CR500 printer as part of an overall system. If contents of the box are missing, contact your Datacard authorized dealer, distributor, or reseller. If you purchased your printer directly from Datacard Group, contact the Datacard Customer Care Center in your region: Americas or Europe, Middle East and Africa Asia Pacific Make sure you have the printer serial number, located on the back of the printer, when you call. For Datacard CardWizard Instant Issuance Software support, call Page 2 Introduction

13 Chapter 2: About the Printer This chapter describes the Datacard CR500 Card Printer. About the Printer on page 4 Unpack the CR500 Printer on page 5 The Exterior of the CR500 Printer on page 8 Inside the Printer on page 9 The Back of the Printer on page 10 Options in the Printer on page 11 CR500 Instant Issuance System Installation and User Guide Page 3

14 About the Printer The Datacard CR500 card printer uses retransfer printing technology to produce highquality, edge to edge printing on a variety of PVC and non PVC card surfaces. The retransfer printing process uses two types of ribbon: a color ink ribbon and a retransfer film. The color ink ribbon is YMCK I (Yellow, Magenta, Cyan, Black, Inhibitor panel). The printer uses these colors to print images on the retransfer film. A heated roller then transfers the image onto a card. The inhibitor panel on the ribbon removes retransfer material in areas of the card that have a magnetic stripe, signature panel, hologram, or smart card chip. The Inhibitor panel also is called Peel off, and the ink ribbon can be identified as either YMCK I or YMCK PO. The CR500 printer can print on one or both sides of the card. Magnetic stripe capability is standard, and the printer can be equipped with optional smart card (including contact and contactless) capabilities. The printer includes three card hoppers that can be loaded with different types of cards, and an exception card slide for printing single cards. When a card job is sent to the printer, it specifies the location from which to pick the card. Page 4 About the Printer

15 Unpack the CR500 Printer Caution: The CR500 Card Printer weighs approximately 47 pounds (21.3 kg). Use care when removing the printer from the shipping container. Ask another person for assistance. Remove the Printer from the Carton The printer is 29 inches (737 mm) wide, and 15 inches (381 mm) deep. Prepare a surface at least that large to hold the printer when it is removed from the carton. Refer to Site Guidelines on page 14 for information on selecting a location for the printer. Remove the ties that hold the top and the bottom of the carton together. Do not cut the ties. 2 1 CR500 Instant Issuance System Installation and User Guide Page 5

16 Use procedure A or B to remove the printer from the shipping carton, depending on the type of carton. Carton A: 1. Unlatch the handle pullouts. 2. Open the handle pullouts. 3. Remove the top of the carton. 4. Remove the inner lining. 5. Pull the cardboard corners outward. 6. Unfold the sides of the carton. 7. Remove the accessories box from lower cushion. 8. Lift the printer from the lower foam cushion and out of the carton. 9. The printer is enclosed in a plastic bag. Remove the bag from around the printer. 10. Remove all packing tape from inside and around the printer. Page 6 About the Printer

17 Carton B: 1. Lift the cover from the carton. 2. Lift the four sided sleeve from around the printer. 3. Remove the corners. 4. Remove the top foam cushion. 5. Remove the accessories box from lower cushion. 6. Lift the printer from the lower foam cushion and out of the carton. 7. The printer is enclosed in a plastic bag. Remove the bag from around the printer. 8. Remove all packing tape from inside and around the printer. Save the shipping carton, straps, and packaging materials. They are required if you need to store, move, or return the printer for service. Replacements might not be available within the time you need. CR500 Instant Issuance System Installation and User Guide Page 7

18 The Exterior of the CR500 Printer O1 Print Unit Concealed Output Stacker Print Unit Door Print Unit Door Latch Power Switch Security Enclosure Security Enclosure Door Security Enclosure Lock The part of the printer that applies images to cards. Printed cards exit the card discharge slot and rest in the Concealed Output Stacker. Lift the flap to remove the card. Open the door to access the ink ribbon and retransfer film cartridges. Lift up to open the Print Unit door. Press the switch to power on/off the printer. Contains the multicard hopper, touch screen, and the reject card area. Provides access to load cards, load supplies, and remove rejected cards. Turn the key in the lock to open the Security Enclosure Door. The door is locked for shipping. Use the key only during setup. After setup, secure the key. After setup, use the application to unlock the Security Enclosure Door. The application you use must have the ability to unlock and lock the printer. The Security Enclosure Door must be opened before you can open the Print Unit door. Page 8 About the Printer

19 Touch Screen Shows the printer status and any messages. Use it to enable printing, clean the printer, view printer settings, and configure network settings. Exception Card Slide Inside the Printer Pull out the tray, place a card, and push it in to use a card that is different from those in the hoppers. Refer to Print Cards Using the Exception Card Slide on page 57 for the steps to follow. Inside the Print Unit Cleaning Unit/Card Cleaning Rollers Removes dust or debris from the cards before printing. Ink Ribbon Cartridge Ribbon Release Button Film Cartridge Film Release Button Concealed Output Stacker Jog Dials Holds the ink ribbon. Press to release and remove the ink ribbon cartridge. Holds the retransfer film. Press to release and remove the retransfer film cartridge. Attach the concealed output stacker to the card output slot and card stacker bracket. Use the dials when clearing a card jam. Return them to the positions shown after use. Refer to Printer Error Recovery on page 124 for more information on clearing card jams. CR500 Instant Issuance System Installation and User Guide Page 9

20 Inside the Security Enclosure Card Weights Hopper 1 Hopper 2 Hopper 3 Place a card weight on cards loaded in each hopper. Always use a card weight to ensure accurate picking and transporting of the card, whether or not cards are loaded in the hoppers. Holds 70 cards. Holds 50 cards. Holds 50 cards. Reject Card Area The Back of the Printer Cards that did not complete successfully are ejected to this secure area. Security Enclosure Power Network Data Port Fan Filter Security Lock Port Print Unit Power Plug the power supply cord into the receptacle. Plug in the network cable. Open to clean the fan filter and maintain card quality. Attach an optional cable lock, such as a Kensington lock, in this location. Plug the power cord into the receptacle. Page 10 About the Printer

21 Options in the Printer The label on the back of the printer provides Information on the options installed in the printer. The CR500 printer always includes the duplex option and bend remedy. The printer also includes a magnetic encoder. A non contact IC encoder, the Duali contact/contactless reader, is optional and uses the contact IC encoder case. CR500 Instant Issuance System Installation and User Guide Page 11

22 Page 12 About the Printer

23 Chapter 3: Installation Requirements This chapter describes the operating environment recommended for your Datacard CR500 Card Printer. Site Guidelines on page 14 Printer Guidelines on page 15 Physical Security on page 16 Network Connection on page 17 Network Security on page 17 Use Datacard CardWizard on page 17 CR500 Instant Issuance System Installation and User Guide Page 13

24 Site Guidelines The location of installation affects the performance of the CR500 printer. When selecting a site for the printer, consider the following guidelines: Place the printer in a clean office environment, with a cleanness Class 8 or better of ISO Using the card printer in dirty or dusty locations may cause print blurring and printhead malfunctions. Place the printer in a location that has access to two A/C outlets and a network port. Avoid locations where there is a possibility of metal objects or other foreign material entering the unit. Avoid locations susceptible to strong vibration or shock. Avoid locations exposed to direct sunlight. Avoid locations exposed to direct fluorescent lighting. Avoid areas near walls with little ventilation. Refer to Ventilation Clearance on page 15. Avoid areas near air conditioners, humidifiers, or heat sources that may cause condensation inside the printer. Avoid locations prone to static electricity, such as a carpeted room. Avoid unstable locations and angled surfaces. Keep the printer off the floor. Operating Environment The performance of the printer is strongly influenced by the environment of the installation location. Install the printer in an environment within the following recommended temperature and humidity ranges: Temperature: 59 F to 86 F (15 C to 30 C), or 63 F to 83 F (17 C to 28 C) if using peel off (PO) ribbon Humidity: 35% to 70%, non condensing, or 35% to 60% if using peel off ink ribbon Caution: Using the printer in an environment with temperatures lower than the recommended range may cause retransfer errors. Using the printer in an environment with temperatures higher than the recommended range may cause print errors, including deformation of the cards and wrinkling of the film. Page 14 Installation Requirements

25 Ventilation Clearance To ensure proper ventilation to the CR500 printer, maintain minimum clearance distances as shown. Ventilation holes are provided for the cooling fans on the bottom and sides of the unit. Install the unit so the sides are at least 7.9 inches (200mm) away from the surrounding wall. Keep the back of the main unit at least 3.9 inches (100mm) away from a wall. Do not place any objects on top of the unit. The printer requires a work surface 45 inches (1.143m) wide and 19 inches (483 mm) deep. Printer Guidelines Keep the equipment powered off and covered when not in use. Leaving power on for long periods without printing might allow fine dust to collect inside the printer. The dust can adhere to cards and cause print blurring. Store all supplies in a clean, cool, and dry location and in the original packaging until you load them in the printer. Keep the original packaging closed. Do not use supplies or cards that have been dropped on the floor or have otherwise become contaminated. Keep all food, liquids, etc. away from the printer. Keep paper and foreign materials off the printer. When cleaning around the printer, prevent debris from entering the printer. CR500 Instant Issuance System Installation and User Guide Page 15

26 Physical Security The CR500 printer includes the following security features: Cable Lock Bolt Down Security Enclosure Lock The printer can be secured with a cable lock, such as a Kensington lock. The loop end can be secured in the environment. The locking end secures on the side of the printer. Follow the instructions included with the lock to install the cable lock. The printer has a bolt down nut inside the Security Enclosure. Refer to Use the Bolt Down Feature on page 34 to use the bolt down security feature. The key shipped with the printer is intended to be used only during setup, to allow supplies loading. After this time, the key must be secured in a manner that complies with Visa security requirements. Refer to Locking and Unlocking the Security Enclosure on page 20. Page 16 Installation Requirements

27 Network Connection The printer is connected to the enterprise network using an Ethernet cable. The area with the printer must have an available network port for the printer. The workstations for printer users must have access to the printer over the network and must have network permission to the printer. Network Security The printer requires use of the HTTPS protocol and does not recognize unsecured communications. If you are asked to specify a port, use port 9111 with browser access to Printer Manager. Printer Manager is a web based service that displays information about the printer and provides setup and troubleshooting tools. Refer to Using Printer Manager on page 141 for complete information about security options in Printer Manager. The CR500 printer provides encryption using HTTPS. The printer and Datacard CardWizard financial instant issuance software are designed to use this level of security. This manual assumes that the HTTPS protocol provides security. If your organization requires additional security, you are responsible for setup and for procedures documenting its use. Use Datacard CardWizard The CR500 printer is used Datacard CardWizard financial instant issuance software, a centralized application that processes card data and obtains the needed authorization from the financial system that manages customer accounts. Refer to your CardWizard documentation for complete information on using CardWizard. CR500 Instant Issuance System Installation and User Guide Page 17

28 Page 18 Installation Requirements

29 Chapter 4: Preparing a Secure Printer This chapter describes how to perform basic tasks that are managed by secure features of the Datacard CR500 printer. Security at Setup on page 20 Locking and Unlocking the Security Enclosure on page 20 Load Cards on page 24 Load Ink Ribbon and Retransfer Film on page 26 CR500 Instant Issuance System Installation and User Guide Page 19

30 Security at Setup The printer is shipped with printing disabled and the physical lock secured. The printer requires a unique activation code to enable printing. Refer to Activate the Printer on page 46 to enable printing. After setup, you must follow your organization s security procedures to load cards and supplies and perform other printer tasks. Locking and Unlocking the Security Enclosure For most tasks, authenticate using the application to unlock or lock the printer Security Enclosure Door. Tips for Success When the printer is powered on and ready and the Security Enclosure door is opened, the Print Unit beeps, the Print Unit Front Panel turns red and displays No card, and Suspended: Printer unlocked displays on the touch screen. After the printer is closed and locked, the touch screen shows Busy, while the printer initializes. When initialization completes, the touch screen displays Ready. Follow your organization s guidelines for tracking the supplies used. Unlock the Printer Using the Key 1. Insert the key in the lock (A). 2. Press and turn the key clockwise (B). Page 20 Preparing a Secure Printer

31 3. Lift the Security Enclosure door to the fully open position. Lock the Printer Using the Key 1. At the printer, close the Print Unit door if it is open. 2. Lower the Security Enclosure door. 3. Insert the key, if needed. 4. Turn the key counterclockwise to lock the printer (A). 5. Remove the key (B). CR500 Instant Issuance System Installation and User Guide Page 21

32 Unlock the Printer Using Authentication 1. Refer to the instructions for your application to unlock the printer using authentication. 2. At the printer, lift the Security Enclosure door. Page 22 Preparing a Secure Printer

33 Lock the Printer After Using Authentication to Unlock the Printer 1. At the printer, close the Print Unit door (A) if it is open. 2. Lower the Security Enclosure door (B) to the closed position. The printer locks automatically when the Security Enclosure door is closed. A B Door sensor and lock pin Caution: The door lock on the security enclosure is engaged via a solenoid located in the lower part of the opening. A sensor detects when the door is open or closed and engages the solenoid. Covering the sensor while the door is open (for example, by placing paper or a hand over it) can cause it to detect that the door is closed and engage the solenoid. Additionally, a bright light, such as a fluorescent light directly over the printer, can engage the solenoid. Closing the security enclosure door with the solenoid engaged can bend the lock pin, preventing it from disengaging again. If the solenoid is engaged while the door is open, reset it by pushing the lock pin back into the open position. It will remain there until you close and lock the door. CR500 Instant Issuance System Installation and User Guide Page 23

34 Load Cards Track cards removed from inventory and loaded in the printer following your organization s card tracking procedure. Follow your organization s guidelines for which cards to load in each hopper. Use the following card handling tips as you load cards into the hopper: Do not touch the surface of cards before printing them. (Oils on hands will reduce printing quality.) Handle cards by the edges or wear the supplied cotton gloves. Cards can stick together. Slide or fan cards to separate the edges. Orient all cards the same way. Load only ID 1 cards of inch (0.75mm) thickness. Load up to 70 cards in hopper 1, 50 cards in hopper 2, and 50 cards in hopper 3. If you plan to use only one hopper, load cards into hopper 3. Do not use cards that are bent or otherwise damaged. Refer to Cards on page 138 for information about supported card materials. Loading Cards The cards are held in position with a card weight. Always use the card weight to ensure that cards are picked and transported properly. 1. Open the Security Enclosure door. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. Remove the card weight from the hopper to load. Follow your organization s guidelines to load the correct cards in hopper 1, hopper 2, and hopper Fan or separate cards before placing them in the hopper. Page 24 Preparing a Secure Printer

35 4. Place cards in the hopper. Refer to the illustration for the correct card orientation. For cards with pre printed images, load cards with the front of the card down and the top of the image toward the Print Unit. For cards with a magnetic stripe, load cards with the stripe up and toward the Print Unit. For cards with a contact smart card chip, load cards with the chip down and toward the back of the Print Unit. 5. Place the card weight on top of the cards. Make sure to place card weights in all hoppers even if you are not using all three hoppers. 6. Load cards in additional hoppers, if needed, following steps 2 through After all supplies are loaded, close the Security Enclosure door to lock the printer. CR500 Instant Issuance System Installation and User Guide Page 25

36 Load Ink Ribbon and Retransfer Film Load Ink Ribbon The first time you load supplies, the printer must be powered on once to cancel Transport Mode and allow the supplies to be loaded. (Transport Mode is used when moving or shipping the printer.) Refer to Power On on page 37 for the steps to follow. Follow these tips when handling ink ribbon: Do not touch the printing surface of the ink ribbon. (Oils on hands will reduce printing quality.) Place the cartridge on a smooth level surface when loading or reloading. Do not place the cartridge on the printer door to prevent damage to the door. Keep unused ink ribbon in the original package until ready for use. Refer to Storage Environment for Supplies on page 136 for information on storing ink ribbon. When the ink ribbon runs out, Ink Run Out displays on the Print Unit Front Panel, and message 165, Ink ribbon out, displays on the touch screen. The right column of the touch screen supplies gauge shows white, not orange. Refer to The Printer Touch Screen on page 58 for information on the touch screen indicators. Refer to Ink Ribbon on page 137 for more information about ordering replacement ribbons. Loading Ink Ribbon Use the following procedure to load ink ribbon cartridges. 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. Open the Security Enclosure (A). 3. On the Print Unit, slide the door latch up (B) and open the Print Unit door (C). Page 26 Preparing a Secure Printer

37 4. Press the ink ribbon cartridge eject button, and remove the orange cartridge. 5. Remove both used ribbon spools from the cartridge (if present). 6. Load the new roll of ink ribbon on the cartridge: a. Put the full spool of ribbon on the orange supply spindle (A). b. Put the empty take up spool on the black take up spindle (B). c. Align ribbon along the three ribbon guides (C). d. Make sure the ribbon panels match the colored diagram (D) in the cartridge. e. Take up any slack by turning the supply knob (E) counterclockwise. Gently pull the take up knob and turn. If slack cannot be removed, check that the supply and take up spools are firmly seated on the spindles. To insert the cartridge into the printer, the film must be tight along the film guides. Turning the supply and takeup knobs help maintain the proper tension. CR500 Instant Issuance System Installation and User Guide Page 27

38 7. Replace the loaded ribbon cartridge in the printer until it clicks into position. 8. Close the Print Unit door. 9. At setup, continue with loading the retransfer film. 10. If replacing ink ribbon, use the Print Unit Front Panel and press Reset and then Enter to initialize the ink ribbon. 11. After all supplies are loaded, close the Security Enclosure door to lock the printer. Load Retransfer Film Use the following tips for handling retransfer film: Store unused film in the original package. The retransfer film cartridge cannot be replaced in a printer that is in Transport Mode. Power the printer on to cancel Transport Mode. Place the cartridge on a smooth level surface when loading or reloading. Do not place the cartridge on the printer door to prevent damage to the door. Do not touch the printing surface of the retransfer film. (Oils on hands will reduce printing quality.) Do not place film on a dusty or dirty surface; dirt can affect print quality. When the retransfer film has run out, Media Run Out displays on the Print Unit Front Panel, and the touch screen displays message 162, Retransfer film out. The touch screen supplies gauge shows the left column white, not green. Page 28 Preparing a Secure Printer

39 Loading Retransfer Film 1. Unlock the printer, if needed. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. Open the Security Enclosure (A). 3. On the Print Unit, slide the door latch up (B) and open the Print Unit door (C). 4. Press the retransfer film cartridge eject button and remove the green cartridge. 5. Remove both used film spools from the cartridge (if present). CR500 Instant Issuance System Installation and User Guide Page 29

40 6. Load the new roll of retransfer film on the cartridge: a. Put the full roll of film on the green supply spindle as shown (A). b. Put the empty take up spool on the black take up spindle (B). c. Align the retransfer film along the three film guides (C). d. Wind two frames of film (D) onto the take up spool. e. Take up slack by turning the take up knob (E) clockwise. Gently pull the take up knob and turn. If slack cannot be removed, check that the supply and take up spools are firmly seated on the spindles. To ease inserting into the printer, the film must be tight along the film guides. Turning the supply and take up knobs help maintain the proper tension. 7. Replace the loaded cartridge in the printer until it clicks into position. 8. Close the Print Unit door. Page 30 Preparing a Secure Printer

41 9. After replacing the film, use the Print Unit Front Panel and press Reset and then Enter to initialize the film. 10. When all supplies are loaded, close the Security Enclosure door to lock printer. Tips for Success To restore the Print Unit when it is in sleep mode, press the USER button on the touch screen or send a card to print. Handle cards by the edges to preserve print quality. Do not touch the print surface with your hands. CR500 Instant Issuance System Installation and User Guide Page 31

42 Page 32 Preparing a Secure Printer

43 Chapter 5: Installing the Printer This chapter describes how to install the Datacard CR500 printer. Perform the steps in this section in the order listed. Use the Bolt Down Feature on page 34 Install the Concealed Card Stacker on page 35 Connect the Power Cords on page 36 Connect the Data Cable on page 37 Power On on page 37 Network Setup on page 40 Verify Network Communication on page 51 Additional Setup Tasks on page 53 CR500 Instant Issuance System Installation and User Guide Page 33

44 Use the Bolt-Down Feature To use the printer s bold down feature, do the following: Obtain a bolt that meets these requirements: The bolt size is 1/4 20 UNC: the diameter is 1/4 inch, with 20 threads per inch. Do not use a metric sized bolt in place of the UNC bolt. The bolt length needs to be the thickness of the work surface, plus the thickness for the washer, plus 9/16 inch (14.3 mm) to accommodate the spacer, plus 1/4 inch (6.3 mm) going into the rivet nut in the printer. The bolt cannot intrude into the printer more than 1 inch (25.4 mm). Obtain a washer to fit the bolt purchased. Use a drill with a bit the appropriate size for the bolt. The hole must be smaller than the 1 1/16 inch (17.46 mm) diameter of the spacer. 1. Determine where to place the printer on the work surface. Refer to Site Guidelines on page 14 for required clearances. Mark the location of the power switch relative to the work surface. 2. Mark the location of the bolt hole. 3. Drill the bolt hole. 4. Place the printer over the drilled hole, aligning the power switch with the marked location from step From under the work surface, insert the bolt through the washer, through the work surface, and through the spacer. 6. Turn the bolt into the rivet nut on the printer base, turning until the bolt is snug but does not cause distortion. Page 34 Installing the Printer

45 Install the Concealed Card Stacker Hang the concealed card stacker with the upper hook on the card discharge slot, and the lower hooks on the card stacker receptacle. The concealed card stacker hides the completed card (and the confidential data on it) until the operator retrieves it. To open the concealed card stacker, use the tab at the bottom of the card stacker and lift it up. Pull out the completed card. CR500 Instant Issuance System Installation and User Guide Page 35

46 Connect the Power Cords Warning: Always use a grounded power outlet that is not shared with other electrical equipment. Caution: Use an Automatic Voltage Regulator (AVR) if there is a possibility of voltage fluctuations. Use an uninterruptible power source rather than an AVR if there is a possibility of frequent power loss. Check the plug. Power cords vary according to model and country of purchase. 1. Plug the power cord into the power receptacle on the back of the printer (A). 2. Plug the round connector from the Power Supply to the back of the Security Enclosure (B). 3. Plug the power cord to the power supply (C). 4. Plug the other end of the power cord into the facility power source (E). 5. Plug the power cord from the printer into the facility power source (D). 6. If this is the first time you are using the printer, power on the printer without installing supplies. Keep the power on for about 30 seconds, and then power off. The printer is shipped in Transport Mode. Ink ribbon and retransfer film cannot be installed in Transport Mode. Powering on the printer cancels Transport Mode. Page 36 Installing the Printer

47 Connect the Data Cable The data cable is an Ethernet cable that connects the printer to the network. 1. Connect one end of the network cable to Network Port (A) on the back of the Security Enclosure. Power On 2. Connect the other end of the network cable to a network port (B). Before powering on the printer, make sure that: The printer is connected to the network. The power cord is securely connected to the Print Unit and appropriate grounded facility power source. The power supply and power cord are securely connected to the Security Enclosure and a grounded facility power source. The Concealed Output Stacker is attached to the printer. Cards are loaded. Refer to Loading Cards on page 24 for more information. The ink ribbon and retransfer ribbon are loaded properly. Refer to Load Ink Ribbon and Retransfer Film on page 26 for more information. You follow your organization guidelines about when to power the printer on and off. Do not bump the Security Enclosure door. Moving the Security Enclosure door can restart the printer. CR500 Instant Issuance System Installation and User Guide Page 37

48 Power On the Printer Press the symbol on the power switch. The printer powers on and begins initializing. O1 The touch screen shows the Initializing message while the printer checks and positions the ink ribbon, retransfer film, and input hopper components. When operation checks are complete, the Busy message displays on the touch screen for approximately two minutes while the retransfer roller and bend remedy roller warm to their operating temperatures. When the printer is completely powered on, the touch screen shows Ready status. Make sure the touch screen displays Ready before sending cards to the printer. The printer can require several minutes between power on and the Ready status. Page 38 Installing the Printer

49 Power Off the Printer Press the O mark on the printer power switch to power off the printer. O1 After approximately 10 seconds, the touch screen becomes dark and the printer fan stops. CR500 Instant Issuance System Installation and User Guide Page 39

50 Network Setup This section describes tasks you need to perform to set up the printer in your network environment. Some tasks must be directed by your network support personnel. Perform these tasks in the order listed. Retrieve the Printer IP Address The Printer IP Address can be assigned automatically by the network (using DHCP) or by network support personnel (Static IP). DHCP (Dynamic Host Configuration Protocol) means that the network assigns the IP address, subnet mask, and gateway address to the printer. Static IP means that you set the IP address, subnet mask, and gateway address assigned by your network support personnel. Refer to Set a Static IP Address (Optional) on page 42 to set an assigned IP address. When the printer is first installed, it is set to use DHCP to assign the IP address automatically. Retrieve the assigned IP address before continuing with other setup tasks. 1. Power on the printer. Refer to Power On on page Begin when the touch screen shows Ready on Line 1 of the display. 3. Press the USER button (a). 4. Press the ENTER key (b). 5. Press the Down Arrow key (c). Page 40 Installing the Printer

51 6. Press the ENTER key (d). 7. Press the Down Arrow key three times (e). 8. Press the ENTER key (f). 9. Press the Down Arrow key (g) 10. Press the ENTER key (h). CR500 Instant Issuance System Installation and User Guide Page 41

52 11. Write down the printer s IP address. 12. Press the USER button (i) repeatedly until Ready displays on Line 1 and the USER button changes from amber to green. Set a Static IP Address (Optional) Your CardWizard application might require that the printer have the same IP address at all times, called a Static IP. The printer is shipped with dynamic addressing. You can change the address method and assign a static IP address using the touch screen or using Printer Manager. This section describes how to use the touch screen to set a Static IP address. Follow these steps only at the direction of your network support personnel. Before You Begin Obtain the following values from network support personnel. Make sure you receive all three values. IP Address Subnet Mask Gateway Address Set the Address Method 1. Power on the printer. Refer to Power On on page Begin when the touch screen shows Ready on Line 1 of the display. Page 42 Installing the Printer

53 3. Press the USER button (a). 4. Press the ENTER key (b). 5. Press the Down Arrow key (c) twice. 6. Press the ENTER key (d). 7. Press the ENTER key (e). CR500 Instant Issuance System Installation and User Guide Page 43

54 8. Press the ENTER key (f). 9. Use the arrow keys, if needed, to display Static IP on line 2. Press the ENTER key (g). 10. Press the ENTER key (h). 11. Enter the assigned IP address: The IP address has 4 bytes, separated by periods. The values shown in the illustration are an example. Use the address values supplied by your network support personnel. Begin with the three digit byte on the left. a. Press the Up Arrow or Down Arrow keys (i) to change the first byte. Page 44 Installing the Printer

55 b. Press the ENTER key (j) to move to the next byte. The address byte shows three digits when it can be changed. c. Repeat steps 11a and 11b for the remaining address bytes. d. When all four bytes are updated, press the ENTER key (k). 12. Press the ENTER key (l) to change the subnet mask, following the process in step 11. After completing the subnet mask, Network displays on line 1 and Gateway Address displays on line Press the ENTER key (m) to change the gateway address, following the process in step 11. CR500 Instant Issuance System Installation and User Guide Page 45

56 14. Press the ENTER key (n) to restart the printer. Activate the Printer To meet Visa security requirements, the printer is shipped with most features disabled. You must obtain the printer activation code and enable the printer to continue setup. Hints & Tips The factory issued activation code is 8 characters. The activation code can contain the numerals 0 through 9, lowercase and uppercase alphabetic characters, and the special characters $ = / +. A printer activation code can be created at another time, such as when shipping to a repair depot; it must be 5 characters or more. Refer to Prepare the Printer for Transport on page 93 for information on setting an activation code. To activate the printer and to enable printing: 1. Obtain the activation code: a. At installation, call Datacard Technical Phone Support at with the printer serial number to obtain the activation code. The printer serial number is located on the back of the printer, as shown. It is a seven character code beginning with AA and followed by five numbers. b. If you are enabling the printer after it has been moved or serviced, contact the person who disabled the printer to obtain the activation code. Page 46 Installing the Printer

57 2. Install the supplies. Refer to Preparing a Secure Printer on page 19 for the steps to follow. 3. Power on the printer. Refer to Power On on page Enter the touch screen menus. a. Begin when the touch screen shows Ready on Line 1 of the display. b. Press the USER button (a). c. Press the ENTER key (b) 5. Enter the Activate menu. a. Press the Down Arrow key (c) until Activate displays on line 2. b. Press the ENTER key (d). CR500 Instant Issuance System Installation and User Guide Page 47

58 c. Press the ENTER key (e) to enter the Enable menu. 6. Enter the activation code. a. Beginning with the left most place, press the Up Arrow or Down Arrow keys (f) to cycle through the numbers and letters of the code. The left arrow symbol is a backspace character and moves the cursor to the previous position. b. Press the ENTER key (g) to move to the next digit on the right. c. Repeat steps 6a and 6b until all characters are correct. Press the ENTER key (g) one more time to position the cursor after the final digit. 7. Press the ENTER key (h) to submit the code. If Request Success displays on line 2 of the touch screen, and the USER light glows steady green, the printer is activated. Page 48 Installing the Printer

59 If another message displays on line 2 of the touch screen, system activation failed. Repeat step 6. If activation fails again, contact Datacard Technical Phone Support at Press the USER button (i) repeatedly until Ready displays on Line 1 and the USER button changes from amber to green. The printer is ready for additional setup and to print cards. Set Up Network Access Work with network support personnel to make sure the printer is set up in your organization: Provide the IP address from the touch screen of the printer. Set up network security, which includes setting up the HTTPS protocol for the printer, for users who communicate with the printer, and for CardWizard. Define network permissions to the printer and the application that runs the printer. Set up Datacard CardWizard Instant Issuance software, to work with the printer. Refer to CardWizard Setup on page 53 for more information. Your organization is responsible for network setup and security. Open Printer Manager The printer IP address can be retrieved before printing is enabled. The printer IP address mode (DHCP or Static) and IP address cannot be changed until printing has been enabled. Refer to Activate the Printer on page 46 for the steps to enable the printer. After network access is set up, open the Printer Manager web service to complete setup tasks. Printer Manager displays information about the printer and provides setup and troubleshooting tools. Printer Manager is available through a web browser. Supported browsers include Internet Explorer v7 and higher and Firefox v3.6 and higher. CR500 Instant Issuance System Installation and User Guide Page 49

60 During normal operation, site personnel should not use Printer Manager unless asked to do so. 1. Get the printer IP address. Refer to Retrieve the Printer IP Address on page Open the web browser on the PC. 3. In the Address area of the browser, type the following: For example: where is the printer IP address. 4. Press the ENTER key. The web browser might display a certificate warning message because the current printer IP address is different from the IP address on the certificate. Click Continue to this website to use Printer Manager. 5. In the Please Log In area, select a Username and enter a password, if required. The default Username is WebUser. WebUser level users can view printer Status information. No password is required. WebAdmin users can print a test card and make some settings changes. For printer setup, choose WebAdmin. A password may be required. WebService users have additional access for settings and troubleshooting. A password is required. 6. Click Log In. Page 50 Installing the Printer

61 7. The Printer Manager Welcome page displays. Refer to Using Printer Manager on page 141 for complete information on using Printer Manager. 8. Continue with Verify Network Communication on page 51. Hints & Tips The access level controls the information that displays and the changes that you can make. If the browser cannot connect to the printer, make sure that: The touch screen displays Ready. Another user does not have a Printer Manager session running on the same printer. A VPN (Virtual Private Network) client is not restricting your access to Printer Manager. Log out of the VPN client and reconnect to your local network, if needed. For security, select Log Out in Printer Manager and close the browser window after logging out. Verify Network Communication Print a Test Card Accessing Printer Manager verifies that your workstation and the printer can communicate over the network. To further verify that the printer works as expected, print a test card. Use Printer Manager to perform other printer setup tasks, as necessary. 1. Begin with Printer Manager open and log in as a WebAdmin user. 2. Select TroubleShooting Test Card. 3. For a simple single side card, make the following selections: For installation testing, select the Card Front (1) column. Select Exception for the Input Hopper Number. Select Color. Select TestPattern1. CR500 Instant Issuance System Installation and User Guide Page 51

62 4. At the printer: a. Pull out the exception card slide and place a plain white card (A) in the slide. A B b. Push the slide all the way in (B), past any resistance, until it reaches the stop position. 5. In Printer Manager, click Run. 6. The printer touch screen changes from Ready to Busy. The printer processes the card and ejects the printed test card in the Concealed Output Stacker. You can print additional test cards by selecting different options in Printer Manager. If a card does not print, and no messages display, contact your network support personnel for assistance. Page 52 Installing the Printer

63 Additional Setup Tasks You might need to set up card features, including: Magnetic stripe format Bend Remedy K Power PeelOff Power Resin Black Mode Retransfer Roller Temp YMC Power Follow the guidance of your system administrator, and make changes only if needed. Refer to Printer Setting Menu on page 147 for information on how to specify these settings in Printer Manager. CardWizard Setup You must define the CR500 printer to the CardWizard Administrator application. Refer to the CardWizard Administrator User Manual and the CR500 Instant Issuance System Setup documents for guidance. CR500 Instant Issuance System Installation and User Guide Page 53

64 Page 54 Installing the Printer

65 Chapter 6: Using the Printer This chapter describes how to perform basic tasks required to operate the Datacard CR500 printer. Initialize Supplies on page 56 Print Cards on page 56 The Printer Touch Screen on page 58 The Touch Screen LCD Menu System on page 60 The Print Unit Front Panel on page 63 The Print Unit Front Panel Menu System on page 66 Use the Print Unit Menus on page 71 CR500 Instant Issuance System Installation and User Guide Page 55

66 Initialize Supplies Print Cards Use the Print Unit front panel to initialize supplies. One initialize action moves both the ink ribbon and retransfer film into the proper position. Initialization also occurs each time you power on the printer. To avoid dirt and dust particles that might adhere to the ink ribbon and retransfer film during loading, move (initialize) the supplies one panel set each time a cartridge is removed from the printer and replaced. The printer detects the type of ink ribbon and retransfer film installed. Print cards after you install the printer and set up printer options, initialize supplies, and set up your card design. Tips for Printing Cards Do not open the printer during the printing operation. Do not power off, unplug, or disconnect the printer during the printing process. Send cards to the printer from Datacard CardWizard financial card software. The software handles the types of information used on cards. The card type in each hopper must be identified to the software. The software tells the printer to pick a card from the hopper in which the required type of card is loaded. If the specified hopper is empty, the printer displays an error. Load cards to continue. The touch screen shows Busy when a card is sent to print. Page 56 Using the Printer

67 Print Cards From CardWizard 1. Follow the instructions in CardWizard to format and save the data for the card. 2. Use CardWizard to send the card to the printer. CardWizard performs verification, prepares the card data for printing, and sends it to the printer. 3. The printer touch screen changes from Ready to Busy. The printer processes the card and ejects the printed card in the Concealed Output Stacker. Print Cards Using the Exception Card Slide Use the Exception Card Slide if you want to print a card that is different from the cards loaded in the hoppers. The Exception Card Slide must be pushed in past the point of resistance until it reaches the stop position. 1. At the printer: a. Pull out the Exception Card Slide and place a card in the slide (A). The magnetic stripe should be up and toward the printer. A B b. Push the slide all the way in (B), past any resistance, until it reaches the stop position. 2. In CardWizard, click Send or Print. 3. The printer touch screen changes from Ready to Busy. The printer processes the card and ejects the printed card in the Concealed Output Stacker. CR500 Instant Issuance System Installation and User Guide Page 57

68 Tips for Success The Print Unit can enter sleep mode. If sleep mode is enabled, sending a card or using the touch screen restores the Ready state. The printer uses one set of panels. Handle cards by the edges to preserve print quality. Do not touch the print surface with your hands. Wear the gloves provided. When printing a test card from the touch screen, always place the card in the Exception Card Slot. The Printer Touch Screen The printer touch screen, located on the Security Enclosure, operates when the printer is powered on. It shows printer status, the printer s menu system, and printer messages or conditions as they are issued. Refer to Messages and Error Recovery on page 99 for message information. The menu system contains several choices for viewing and changing printer settings, and performing simple maintenance tasks, including printing a test card. Refer to The Touch Screen LCD Menu System on page 60 for more information. User Button and Light The touch screen USER button displays with a border of light that indicates the system status. Use the USER button to: Suspend the printer when it displays Ready. Clear a message. Clear all messages press the USER button for at least 2 seconds. Page 58 Using the Printer

69 Cancel all cards currently printing press and hold the USER button for several seconds. (Make sure this action is allowed by your organization.) See whether the printer is ready, busy printing, or not available. Indicators include the following: Off (not visible) Green The printer is off. The printer is ready. Blinking green The printer is busy. Amber The printer is not ready. Blinking Amber The printer has an error. Down Arrow, Up Arrow, and Enter Keys Ribbon Light Use the arrow keys to move through the printer menu system. Press the ENTER key to make a selection. Refer to The Touch Screen LCD Menu System on page 60. The ribbon light indicates the status of the ribbon in the printer. It glows green when the print ribbon is low and glows amber when there is a problem with the ribbon, such as end of ribbon. Off Ribbon is okay. Green Ribbon is low less than 10% remains. The percent of ribbon remaining required for notification can be changed using Printer Manager. Refer to FrontPanel on page 154. Amber Ribbon is out or broken. Blinking Amber The printer problem applies to the ribbon. CR500 Instant Issuance System Installation and User Guide Page 59

70 Card Light The card light indicates the status of the cards in the printer. It blinks amber when the printer has a card problem, such as when the printer is out of cards. Off Cards are okay. Rapid Blinking Green Insert card using exception card slide. Blinking Amber The printer problem applies to cards. Supplies Status Light The touch screen status light shows the status of the retransfer film and ink ribbon. The green bar shows the amount of retransfer film available: 100% available, 75% available, 50% available, or 25% available. The orange bar shows the amount of ink ribbon available: 100% available, 75% available, 50% available, or 25% available. The Touch Screen LCD Menu System The touch screen of the printer includes a 2 line LCD text display with keys. When the printer is not actively printing cards, the menu system is available. Refer to The Printer Touch Screen on page 58 for more information about other features of the touch screen. Use the LCD menu for tasks, including: View the printer IP address. Refer to Retrieve the Printer IP Address on page 40. View the printer serial number. Set the IP address type. Refer to Set a Static IP Address (Optional) on page 42. Print a test card. Page 60 Using the Printer

71 LCD Menus The menu system has four major branches: Use the Maintenance menu to print a test card. Use the Status menu to see settings and data about the printer. Use the Configuration menu to change network and printer settings. Use the Activate menu to enable or disable printing. Refer to Activate the Printer on page 46 and Prepare the Printer for Transport on page 93. Tips for Success The menu system can be accessed when Ready displays on Line 1 of the touch screen. To leave a selection without changing the value, do one of the following: Press the up or down arrow key to scroll to Exit and then press the ENTER key. Press the USER button. CR500 Instant Issuance System Installation and User Guide Page 61

72 Card Counts The Touch Screen Status menu displays card counts that track cards. Use these counts for tracking cards within the organization. Printer Manager also provides the same card count information. Refer to Status Menu on page 145 for information on displaying card counts in Printer Manager. The Print Unit front panel also displays card counts. These are lifetime counts of the number of cards that have gone through the printer. They are not related to the CR500 card counts. Do not use the Print Unit counts for tracking cards. Messages and Conditions When the printer cannot process the card sent, it issues a message. Messages display on the touch screen. The printer displays a short description and a message number for each message. If more than one message was issued, the next message displays after you correct the first issue and press the USER button. The printer issues messages that focus on recovering from problems. The Print Unit also has a front panel, which might display more detailed messages. The message on the touch screen directs you to the Print Unit front panel when needed. Refer to Messages and Error Recovery on page 99 for messages and how to recover from them. Page 62 Using the Printer

73 The Print Unit Front Panel The Print Unit Front Panel is available when the Security Enclosure door is open. It has two lines of text, indicators for key functions, and symbols for connection type and lock status. At times, you must use the Print Unit Front Panel. Line 1 Line 2 Key Indicator Speaker Connection Locked? Key Line 1 of the display shows the current printer status, such as Ready or Printing. It also shows the menu name when using menus. Line 2 shows card counts or choices available if you are using menus. Line 3 presents key indicators, the connection symbol, and the current lock state. The display background color changes according to the Print Unit current state. The background is: Bright green during power on. Bright blue when the printer is operating normally, including during initialization, preheating, and printing cards. Medium blue when recovering from errors. Red on Print Unit error. CR500 Instant Issuance System Installation and User Guide Page 63

74 Connection and Lock Symbols The Print Unit displays the following symbols that indicate its status. The Print Unit is connected through a USB cable. The Print Unit does not have an IP address. This is the proper configuration for the CR500 printer. Card data is sent to the Print Unit using the USB cable. The Print Unit is connected through a USB cable. The Print Unit has an IP address. The Print Unit is connected through a network connection. The Print Unit does not have an IP address. If this symbol displays, power off the printer, wait several seconds, and power on the printer again. Using a network connection interferes with operation of the Print Unit with the Security Enclosure. The Print Unit is connected through a network connection. The Print Unit has an IP address. If this symbol displays, power off the printer, wait several seconds, and power on the printer again. Using a network connection interferes with operation of the Print Unit with the Security Enclosure. The Print Unit is unlocked. (The Print Unit lock is different from the Security Enclosure lock.) The Print Unit is locked. If this symbol displays, contact your service provider for assistance. If the laminator symbol displays, contact your service provider for assistance. Keys The indicators for key functions display as white text on a black rectangle. The Cleaning display example shows how indicators describe the keys. Page 64 Using the Printer

75 The keys can have the following functions: Reset Menu Enter Initializes the printer. Use the Reset key after loading supplies or after an error occurs. Press Menu to use the printer menus. Continue to press Menu to access the settings in the order listed in The Print Unit Front Panel Menu System on page 66. Displays the next, lower level of the menu. Next View the next item in the menu. Arrow Keys Exit Return Change Use the Up and Down Arrow keys to display list items within a menu level. Exits the current menu or menu selection and returns to the previous menu selection. Confirms the user selection. The setting takes effect. Makes it possible to change settings. Scroll Scroll Right Makes it possible to scroll through values for a setting. Moves the cursor one position to the right. Scroll Left Moves the cursor one position to the left. Speaker The speaker provides an electronic beep that indicates that an error has occurred, or confirms that settings have been saved. CR500 Instant Issuance System Installation and User Guide Page 65

76 The Print Unit Front Panel Menu System To use the menus, follow these steps: Press Menu when Ready displays. Press Menu to display >Cleaning> (the first menu choice) on the Front Panel. The > symbol following a menu selection indicates that there are subcategories within the selection. Press Next to view these options. For example, press Enter when >Cleaning> displays to view the Cleaning submenu. Press Next in the Cleaning submenu to view cleaning choices. Press Exit at any time to exit that level of the menu system. Continue to press Exit to return to Ready status. Menu Display Settings Function Cleaning Rollers MG Select Rollers to start the cleaning function to clean the card feed rollers and heated rollers. Refer to Clean the Print Unit on page 84. Select MG to clean the magnetic (MG) head when using magnetic stripe cards. Refer to Clean the Magnetic Stripe Head on page 88 for the steps to follow. Counter Reset OK? Press Enter to reset the Free counter and Error counter. Test Print Download Test Pattern Printer Setting Network Setting DO NOT USE. Use either the touch screen LCD menu (refer to LCD Menus on page 61) or Printer Manager (refer to Test Card on page 163) to print test cards. To prepare the printer for a firmware download, press Enter. A separate firmware update utility is used to update the printer firmware. Refer to Printer Manager Updates on page 165 for more information. DO NOT power off the printer while the firmware is being downloaded. Page 66 Using the Printer

77 Menu Display Settings Function Transport Mode OK? Set the Transport Mode when moving or shipping the printer. Press Return to place the printer in Transport Mode. Please, power off displays on the Front Panel. The Transport Mode is cancelled when the printer is powered back on. Refer to Prepare the Printer for Transport on page 93 for information on preparing the printer for transporting it. Media Ink Type: YMCK YMCK-PO YMCKK YMCK-UV Film Type: 1000 Card Thickness: Standard Thin Displays the ink ribbon and retransfer film that are loaded in the printer. Press the NEXT key to scroll to the next media type. The CR500 printer support only YMCK-PO ink ribbon. (The printer detects the type of ink ribbon; it cannot be set.) Datacard retransfer film is available in 1000 frames per roll. Only Standard ID-1 cards, inch (0.76mm) thick, are supported. Print YMC Level Displays the value set using Printer Manager. Refer to Print Settings on page 155 for more information on specifying Print settings. Black level Black mode UV Level PO Level Displays the value set using Printer Manager. Refer to Print Settings on page 155. Displays the value set using Printer Manager. Refer to Print Settings on page 155. Not supported. Displays the value set using Printer Manager. Refer to Print Settings on page 155. CR500 Instant Issuance System Installation and User Guide Page 67

78 Menu Display Settings Function Retransfer Temp Level Displays the value set using Printer Manager. Refer to Print Settings on page 155 for more information on specifying Retransfer settings. Speed (Front) Speed Front (UV) Speed (Back) Speed (B-UV) MG Peel Mode Standby: Front Wait Back Wait Backside Cool: On Off Displays the value set using Printer Manager. You must have WebService-level access to set this value. Refer to Start Printer Manager on page 142. Not supported. Displays the value set using Printer Manager. You must have WebService-level access to set this value. Refer to Start Printer Manager on page 142. Not supported. Displays the value set using Printer Manager. Refer to Print Settings on page 155. Not supported. Displays the value set using Printer Manager. Refer to Print Settings on page 155. Bend Remedy Temp Level Displays the value set using Printer Manager. Refer to Print Settings on page 155 for more information on specifying Bend Remedy settings. Heat Roller Speed Power Saving: Off or up to 60 minutes HR Control: Enable Disable Displays the value set using Printer Manager. You must have WebService-level access to set this value. Refer to Start Printer Manager on page 142. Displays the value set using Printer Manager. Refer to Behavior on page 153 for information on specifying the power saver mode. Displays the value set using Printer Manager. Page 68 Using the Printer

79 Menu Display Settings Function Setting Display: Displays the printer settings. Mode: Counter Laminator State Counter: Total Cnt Head Cnt Free Cnt Cleaning Cnt Error Cnt Contrast Buzzer: On Off Unit No.: No. 1 No. 10 Only the Counter setting is supported. Use the Up and Down Arrow keys to select the card counter type: Total is the default setting and displays the number of cards printed. The Total counter cannot be reset. Head displays the number of complete dye panels. The Head counter cannot be reset; however, it automatically resets itself when the printhead is replaced. The Free counter displays the number of cards that have printed. You can reset the Free counter. Displays the Front Panel contrast using 7 gradations from 3 (low contrast) to +3 (high contrast). The default setting is 0. Displays whether the electronic beep sound is On or Off. The sound can indicate an error or can confirm a menu selection. DO NOT USE. The Unit No defaults to 1 for the CR500 printer. CR500 Instant Issuance System Installation and User Guide Page 69

80 Menu Display Settings Function Option MG MG: None ISO IC Antenna: None Installed IC Contact: None ISO Type Contact IC R/W: None Installed Bend Remedy HR: None Installed Turn Over: None Installed ISO Type: Loco Hico JIS Type: Loco Hico Retry Count: 0, 1, 2, 3 Displays the type of magnetic encoder installed. Displays whether the contactless card option is installed: None: a contactless card option is not installed. Installed: a contactless smart card option is used. Displays whether the contact card option is installed: None: a contact card option is not installed. ISO type: the type of contact card option installed. Displays whether the contact card R/W option is installed: None: the R/W option is not installed. Installed: an Internal Contacts for External Reader option is installed. Displays whether the bend remedy option is installed. Displays whether the turnover (duplex) option is installed. Displays the coercivity value set using Printer Manager for writing data to magnetic stripe cards (if the magnetic stripe option is installed): Loco: 238 x 10 2 [A/m] (300[Oe]) Hico: 218 x 10 3 [A/m] (2750[Oe]) Refer to MagStripeGeneral on page 161 for more information. Displays the value set using Printer Manager. Refer to MagStripeGeneral on page 161 for information on setting the retry value. Page 70 Using the Printer

81 Menu Display Settings Function Network Printer Name DO NOT USE Host IF: USB LAN IPv4 IPv6 This must be set to USB. DO NOT USE DO NOT USE Tips for Success The Print Unit can be set to use a network connection. Make sure the Print Unit is set to use USB. Selecting to use a network connection interferes with operation of the Print Unit with the Security Enclosure. It s possible to assign a security key (number) to the Print Unit using the Front Panel. DO NOT assign a security key to the Print Unit. Doing so interferes with operation of the Print Unit with the Security Enclosure. If a security key number is assigned, contact your service provider for assistance. For values that are set using Printer Manager, refer to Using Printer Manager on page 141. Use the Print Unit Menus The Print Unit Front Panel menu system allows you to specify settings that affect how cards are printed. Apply a Second Retransfer Layer To increase the durability of a card, you may want to apply a second retransfer layer to the front and/or back of the card during printing. Use the Front Panel menus to change the printer settings to perform this process. Do not plan to apply a second retransfer layer to a card if it has a magnetic stripe, signature panel, hologram, or smart card chip. When you use peel off ribbon on the card because it has a magnetic stripe, signature panel, hologram, or smart card chip, the second retransfer layer is not applied. The printer does not provide a notification that the second layer is not being applied. Make sure you are familiar with your card design before proceeding with the following steps. CR500 Instant Issuance System Installation and User Guide Page 71

82 1. Start with the printer on and the Print Unit Front Panel showing Ready. Press the Menu and center keys simultaneously for several seconds. 2. Release the Menu key first to place the Print Unit in Maintenance mode. 3. Press Enter once. The Offset Prt Y menu displays. 13X 4. Press Next 13 times to display the Overcoat menu. Page 72 Using the Printer

83 5. Press Enter to display the Mode (Front) menu. To apply an additional retransfer layer to the front of the card, press Change. 6. Press the down arrow key once to change Line 2 to On and then press Return to accept the change. 7. The Mode (Back) menu displays next. To apply an additional retransfer layer to the back of the card, press Change. 8. Press the down arrow key once to change Line 2 to On and then press Return to accept the change. CR500 Instant Issuance System Installation and User Guide Page 73

84 9. Print several cards to verify that the second retransfer layer is being applied properly. The success of the retransfer can vary depending on the card material used. You may need to adjust the front and back speed of retransfer to get an acceptable card. Lowering the speed can enhance the retransfer, but the stronger heat that results may cause the card to deform. Increase or decrease the speed values, as needed, to determine the best retransfer results for your card type. To change the speed values, continue with step The Speed (Front) menu displays next. To change the front speed, press Change. 11. Press the down arrow to change the speed and then press Return to accept the change. 12. The Speed (Back) menu displays. To change the back speed, press Change. Page 74 Using the Printer

85 13. Press the down arrow to change the speed and then press Return to accept the change. 14. Print additional test cards to check your settings and verify that the retransfer film is being applied properly. Continue to adjust the settings until you are satisfied with your cards. 15. Press Exit three times to return the Print Unit to Ready. CR500 Instant Issuance System Installation and User Guide Page 75

86 Page 76 Using the Printer

87 Chapter 7: Taking Care of Your Printer This chapter provides information to help you maintain the Datacard CR500 printer for optimal performance. Remove Rejected Cards on page 78 Cleaning Schedule for Printer on page 79 Supplies Required on page 80 Clean the Printer on page 80 Prepare the Printer for Transport on page 93 CR500 Instant Issuance System Installation and User Guide Page 77

88 Remove Rejected Cards The printer stores rejected cards in the Security Enclosure. Follow your organization s procedures for when to remove rejected cards and how to track them. 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. Remove rejected cards from the reject card tray. 4. Close and secure the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 5. Follow your organization s procedures to track the cards removed and to dispose of them. Page 78 Taking Care of Your Printer

89 Cleaning Schedule for Printer Clean parts of the printer using the schedule in the following table. When the printer is not in use, turn off the power, let the printer cool, and cover the printer with the plastic shipping bag to keep dust and other debris out of the printer. Task Schedule Description *Card Cleaning Rollers/ Cleaning Unit Every 200 cards or when you change the ink ribbon Yearly Wash the blue cleaning rollers with water. Then, clean using the dual-sided cleaning card and cleaning swab if debris remains on the rollers. Refer to Clean the Card Cleaning Rollers and Cleaning Unit on page 80. Replace the cleaning unit yearly, or more often if it is no longer cleaning effectively. *Multicard Hopper Every 200 cards Clean as described in Clean the Multicard Hopper on page 83. Print Unit: Card Load Roller Card Feed Roller Heated Roller Every 200 cards or when you change the ink ribbon Clean every time you change the ink ribbon. With heavy use, clean more frequently. Refer to Clean the Print Unit on page 84. *Magnetic Stripe Head After every 1000 encoded cards *Thermal Printhead After every 1000 printed cards Clean the magnetic stripe head as described in Clean the Magnetic Stripe Head on page 88. Clean as described in Clean the Thermal Printhead on page 91. *Printer Fan Filter Wash regularly; replace yearly Wash the filter as described in Clean the Print Unit Fan Filter on page 92. Replace the filter every year, or whenever the foam begins to deteriorate. * May need to be cleaned more often depending on the type of card stock used and the environment. CR500 Instant Issuance System Installation and User Guide Page 79

90 Supplies Required Supply Part Number Clean the Printer Cleaning Kit Single-Sided Cleaning Cards (10 in pack) Dual-Sided Cleaning Cards (10 in pack) Magnetic Stripe Cleaning Cards (10 in pack) Cleaning Swabs (5 in pack) Isopropanol (90%) Lint-free Cleaning Wipes This section provides information on proper care and cleaning of the CR500 printer. Each CR500 printer includes one cleaning kit (Part number ) when it is shipped. The kit contains the supplies you need to clean the printer. Order additional cleaning supplies as you need them. Clean the Card Cleaning Rollers and Cleaning Unit The cleaning unit, located inside the printer door, removes lint and other debris from the cards before printing. Use the following procedure to clean the unit. 1. Unlock and open the Security Enclosure door. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. Open the Print Unit door and pull out the green cleaning unit. Page 80 Taking Care of Your Printer

91 3. Clean the rollers. a. Rinse the blue cleaning rollers with water. Gently rub the rollers under running water. Caution: Do not use detergents, which can damage the rollers. b. Allow the card cleaning rollers to dry thoroughly. c. If debris remains on the rollers, use the dual sided cleaning card. Remove the protective paper from both sides of the cleaning card. d. Insert the cleaning card into the rollers of the cleaning unit. CR500 Instant Issuance System Installation and User Guide Page 81

92 e. Move the cleaning card back and forth through the rollers until all debris possible is removed. If you have trouble running the cleaning card through the rollers, remove a jog dial from the printer and use it to turn the rollers with the card in place. f. If any debris still remains, use a cleaning swab to clean the rollers until no debris is visible. g. If you use the cleaning swab to clean the rollers, rinse the rollers under running water again to remove any traces of isopropanol left by the swab. Allow the rollers to dry completely before reinstalling the cleaning unit. 4. Reinstall the cleaning unit with the blue rollers facing to the right. 5. Replace the jog dial if it was removed. 6. Close the Print Unit door and the Security Enclosure door to lock the printer. or Continue with the next step in the cleaning process. Page 82 Taking Care of Your Printer

93 Clean the Multicard Hopper The multicard hopper holds cards before they are printed. Clean the hoppers every 200 cards or when you notice debris on cards. 1. If closed, open the Security Enclosure door. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. Remove all cards from the multicard hopper. Track the hopper in which cards were placed so you can replace them after cleaning. 3. Prepare a cleaning card by folding a magnetic stripe cleaning card. Do not apply any type of fluid to the card. 4. Clean the tracks: a. In hopper 1, insert the folded card and push it all the way along the track, toward the Print Unit (A). Remove the card. b. In hopper 2, insert the folded card and push it all the way along the track, toward the Print Unit (B). Remove the card. c. In hopper 3, insert the folded card and push it all the way along the track, toward the Print Unit (C). Remove the card. CR500 Instant Issuance System Installation and User Guide Page 83

94 5. Using the clean end of the card, clean the front track (D), following the instructions in step Discard the used cleaning card. 7. Close the Security Enclosure door to lock the printer. or Clean the Print Unit Continue with the next step in the cleaning process. The single sided, adhesive cleaning card cleans the card load roller, the Print Unit card feed rollers, and the heated roller. The card load roller moves cards into the Print Unit. The card feed rollers move the card through the printer. The heated roller provides the heat that transfers the film to the card. Refer to Print Unit Roller Layout on page 123 to find the location of the rollers. Use a single sided, adhesive cleaning card to perform this procedure. 1. Before beginning this procedure, do the following: Clean the cleaning unit as described in Clean the Card Cleaning Rollers and Cleaning Unit on page 80. Clean the multicard hopper as described in Clean the Multicard Hopper on page If closed, open the Security Enclosure door. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 3. Power off the printer. Wait approximately 10 to 20 minutes for the printer to cool down. Do not clean the heated roller while it is hot. Allow the printer to cool, or perform cleaning before the heated roller reaches operating temperature. Page 84 Taking Care of Your Printer

95 4. Remove the retransfer film cartridge a. On the Print Unit, slide the door latch up and open the Print Unit door. b. Press the retransfer film cartridge eject button and remove the retransfer film cartridge. c. Close the Print Unit door. 5. Remove the cards from the multicard hopper. Keep the Security Enclosure cover open. 6. Remove the concealed card stacker. 7. Pull out the Exception Card Slide. CR500 Instant Issuance System Installation and User Guide Page 85

96 8. Remove the protective paper from the single sided cleaning card (A). Caution: Do not use the larger dual sided cleaning card to clean the printer. Inserting the dual sided cleaning card into the printer will damage the printer. 9. Insert the cleaning card into the Exception Card Slide with the sticky side up. Push it in until the end of the card rests in the slot (B). 10. Push the Exception Card Slide in, past the resistance until it reaches the stop position (C). 11. Push the card to the Print Unit card feed roller (D). Stop when the card is just under the roller (E). 12. Power on the printer. The message Film Search A1 displays on the Print Unit front panel. 13. Use the Print Unit front panel to run the cleaning card: a. Press Menu to display Cleaning. b. Press Enter to display Rollers OK?. Page 86 Taking Care of Your Printer

97 c. Press Return to display Film checking followed by Cleaning Start OK. d. Press Return. The Print Unit pulls the cleaning card into the Print Unit and cleaning begins. If the card is not pulled into the unit and no errors display, lightly push the card until the roller catches it and the card moves into the unit. e. The card is discharged from the output area and Cleaning Start OK displays. f. Turn the card over and place it the Exception Card Slide with the sticky side facing down. Follow steps 10 and 11 to position the cleaning card. g. Repeat steps a through e. Use a cleaning card one time only. Using a dirty one can damage the rollers. 14. When the cleaning card is discharged, press Exit to end the cleaning process. 15. Continue with the magnetic stripe cleaning procedure. Refer to Clean the Magnetic Stripe Head on page 88. or Prepare the printer for use. a. Reinstall the retransfer film cartridge. b. Close the Print Unit door. c. On the Print Unit front panel, press Exit to return to the top level of the menu system. If an error displays on the front panel, press Reset and Return. The printer initializes. d. Replace the concealed card stacker. e. Replace the cards in the multicard hopper. f. Close the Security Enclosure door to lock the printer. CR500 Instant Issuance System Installation and User Guide Page 87

98 Clean the Magnetic Stripe Head Use a magnetic head cleaning card to perform the cleaning procedure. When the cleaning card becomes dirty, replace it. Using a dirty one can damage the head. 1. If closed, open the Security Enclosure door. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. If cards are in the multicard hopper, remove them. Keep the Security Enclosure cover open. 3. Pull out the Exception Card Slide. 4. Place three or four drops of isopropanol on the stripe of the magnetic head cleaning card. 5. Insert the cleaning card: a. Place the card in the Exception Card Slide and push the card in until the end of the card rests in the slot (A). Page 88 Taking Care of Your Printer

99 b. Push the Exception Card Slide in, past the resistance until it reaches the stop position (B). c. Push the card to the Print Unit card feed roller (C). Stop when the card is just under the roller (D). Optionally, you can insert the magnetic stripe cleaning card in hopper At the Print Unit: a. Press Menu to display Cleaning. b. Press Enter, then press Next to display the MG option. CR500 Instant Issuance System Installation and User Guide Page 89

100 c. Press Return to start the cleaning process. The Print Unit pulls the cleaning card into the Print Unit and cleaning begins. d. After the Print Unit ejects the card into the reject tray, press Exit to end the cleaning process. 7. Continue with the next step in the cleaning process. or If the card is not pulled into the unit and no errors display, lightly push the card until the roller catches it and the card moves into the unit. Prepare the printer for use. a. Close the Print Unit. b. On the Print Unit front panel, press Exit to return to the top level of the menu system. c. Replace the output hopper. d. Replace the cards in the multicard hopper. e. Close the Security Enclosure door to lock the printer. Page 90 Taking Care of Your Printer

101 Clean the Thermal Printhead Caution: The thermal printhead can be damaged by an electrostatic charge. Discharge yourself by touching the Print Unit frame before cleaning the printhead. 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. 2. Power off the printer. 3. Open the Security Enclosure door. 4. Open the Print Unit door. 5. Press the ink ribbon cartridge eject button and remove the ink ribbon cartridge. 6. Press the retransfer film cartridge eject button and remove the retransfer film cartridge. 7. The thermal printhead is located in the area between the ink ribbon and retransfer film cartridge slots. Carefully insert the cleaning swab and gently wipe the thermal printhead. Discard the swab after you finish cleaning the printhead. Caution: Never use metal or abrasive materials to clean the thermal printhead. 8. Reinstall the ink ribbon and retransfer film cartridges. 9. Close the Print Unit door and power on the printer. 10. On the Print Unit front panel, press Exit to return to the top level of the menu system. 11. Close the Security Enclosure door to lock the printer. CR500 Instant Issuance System Installation and User Guide Page 91

102 Clean the Print Unit Fan Filter The Print Unit has a fan filter to prevent airborne particles from entering the print area. Clean the filter regularly and replace it yearly. 1. Remove the external fan cover and filter Rinse the filter under running water. 3. Allow the filter to dry thoroughly. 4. Replace the fan filter and cover in the printer. Page 92 Taking Care of Your Printer

103 Prepare the Printer for Transport Use saved packaging materials to prepare the printer for transport. Transport includes moving the printer from one location to another, and sending the printer for service. To prepare the printer: Disable printing Disable Printing Package the printer To meet Visa security requirements, the printer is shipped with most features disabled. When you send the printer to another location, disable the printer and provide the activation code to the recipient. Hints & Tips The printer activation code must be 5 characters or more. The code can contain the numerals 0 through 9, lowercase and uppercase alphabetic characters, and the special characters $ = / +. To disable the printer: 1. Begin with supplies installed and the printer powered on. 2. Enter the Touch Screen menu. a. Begin when the touch screen shows Ready on Line 1 of the display. Press the USER button (a). b. Press the ENTER key (b). CR500 Instant Issuance System Installation and User Guide Page 93

104 3. Enter the Activate menu. a. Press the down arrow key (c) until Activate displays on line 2. b. Press the ENTER key (d). Activate displays on line 1 and Enable displays on line 2. c. Press the down arrow key (e) to display Disable on line 2. d. Press the ENTER key (f). Page 94 Taking Care of Your Printer

105 4. Enter the activation code. a. Beginning with the left most place, press the up arrow or down arrow keys (g) to cycle through the numbers and letters of the code. The left arrow symbol is a backspace character and moves the cursor to the previous position. b. Press the ENTER key (h) to move to the right. c. Repeat steps 4a and 4b until you have entered the code you ve selected. 5. Press the ENTER key (h) to submit the code. If Request Success displays on line 2 of the touch screen, the printer is disabled. If another message displays on line 2 of the front panel, system deactivation failed. Repeat step Exit the menu system. Press the USER button repeatedly until Ready displays on Line 1 and the USER button changes from amber to green. CR500 Instant Issuance System Installation and User Guide Page 95

106 Prepare and Package the Printer 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. On the Print Unit, slide the door latch up and open the Print Unit door. 4. Remove the printer ink ribbon cartridge, and then remove the ink ribbon supply from the cartridge. Place the empty cartridge back into the printer. Refer to instructions in Load Ink Ribbon on page Remove the retransfer film cartridge from the printer and remove the film supply from the cartridge. Place the empty cartridge back into the printer. Refer to the instructions in Load Retransfer Film on page In the Security Enclosure, remove all cards and card weights. Place the card weights in the accessory tray of the shipping carton. Slide the Exception Card Slide all the way in. 7. Close the door to the Print Unit. 8. Press Reset to display the Initialize OK message. 9. Push Enter to display the Film Search error message. 10. Set the Print Unit to Transport Mode using the Front Panel. Refer to The Print Unit Front Panel Menu System on page Close the Security Enclosure to lock the printer. 12. Power off the printer. 13. Disconnect the power and data cables from the printer. 14. Remove the Concealed Output Stacker. a. Press the bottom of the stacker up to release it. b. Pull the stacker away from the printer. 15. Allow the unit to cool before packaging it for transport. Page 96 Taking Care of Your Printer

107 Package the Printer 1. Place the printer in the plastic bag. 2. Package the printer in the original shipping carton. OR 3. Secure the shipping straps. 4. Provide the activation code to the recipient of the printer. CR500 Instant Issuance System Installation and User Guide Page 97

108 Page 98 Taking Care of Your Printer

109 Chapter 8: Messages and Error Recovery This chapter provides information to help you respond to the printer and laminator messages and explains how to recover from a problem. Touch Screen Messages on page 100 Print Unit Roller Layout on page 123 Printer Error Recovery on page 124 CR500 Instant Issuance System Installation and User Guide Page 99

110 Touch Screen Messages The printer displays messages on the touch screen. Some messages, such as Card Hopper Empty 113 are corrected in the Security Enclosure. Other messages, such as Retransfer Film Out 162 are corrected in the Print Unit. Messages on the Printer Other Messages The printer touch screen shows a short description and a number for each message. If more than one message was issued, the next message displays after you correct the problem and press the User button. The printer issues messages that focus on recovering from problems. The Print Unit also has a front panel, and it can display more detailed messages that are specific to the Print Unit. The following list describes the source and possible causes for each message to help you determine if you need to check the Print Unit to correct the condition. CardWizard can display messages. Other printers can display messages if more than one printer is installed. The touch screen displays Busy when the printer is preparing for the Ready state. The Print Unit displays messages during error recovery and when the Security Enclosure door has been opened. Common messages include: No Card displays when the Security Enclosure Door is open and the printer is ready to print cards. Initializing displays when the Print Unit is powering on. Preheating displays when the Print Unit is heating the retransfer roller. Sleeping displays when the Print Unit has removed power from the retransfer and bend remedy roller. This conserves supplies and power. Page 100 Messages and Error Recovery

111 Quick Link to a Message Number Message Text Message 100: Request not supported on page 102 Message 101: Job could not complete on page 102 Message 103: Printer problem on page 103 Message 104: Critical problem on page 103 Message 105: Magstripe data error on page 105 Message 106: Magstripe data not found on page 105 Message 108: Magstripe read no data on page 106 Message 111: Card not picked on page 106 Message 112: Card hopper empty on page 106 Message 113: Close cover to continue on page 107 Message 114: Cover opened during job on page 107 Message 115: Wait for print temperature on page 107 Message 116: Magstripe not available on page 108 Message 118: Print ribbon type problem on page 108 Message 119: Print ribbon not supported on page 108 Message 120: User paused the printer on page 109 Message 121: Print ribbon ID problem on page 109 Message 122: Magnetic stripe format problem on page 109 Message 123: Insert new card side 1 up on page 110 Message 124: Insert same card side 1 up on page 110 Message 149: Option not installed on page 110 Message 150: Print while unlocked on page 111 Message 151: Failed to lock on page 111 Message 154: Print unit not available on page 112 Message 155: Room temperature too low on page 112 Message 156: Printer warming up on page 113 Message 157: Input hopper card jam on page 113 Message 158: Check print unit front panel on page 113 Message 159: Print unit card jam on page 115 Message 160: Set print unit to download on page 116 Message 161: Retransfer film problem on page 116 Message 162: Retransfer film out on page 116 Message 163: Clear hopper card track on page 117 Message 164: Ink ribbon problem on page 117 Message 165: Ink ribbon out on page 117 Message 169: Move retransfer film one panel on page 118 Message 173: Improper shutdown on page 118 Message 181: Input Hopper Problem on page 118 Message 182: Input Hopper Jam two cards on page 119 Message 183: Input Hopper jam card lost on page 119 CR500 Instant Issuance System Installation and User Guide Page 101

112 Message 184: Input Hopper jam card at exit on page 119 Message 185: Input Hopper jam print input on page 120 Message 186: Input Hopper Jam at exit on page 120 Message 187: Input Hopper Jam print input on page 120 Message 188: Input Hopper Jam print input on page 121 Message 189: Input Hopper jam card at exit on page 121 Message 190: Input Hopper jam exception on page 121 Message 191: Input Hopper jam print input on page 122 Message 192: Input Hopper Jam exception on page 122 Message 193: MultiHopper Jam two cards on page 122 Message 194: MultiHopper jam card lost on page 123 Message 100: Request not supported Message Source / Text Possible Cause Solution Security Enclosure Security Enclosure Print Unit: Security Key 21, 22, or 23 A message was cleared while the printer was open. The setting change requested is not supported. A security key (number) was set in the Print Unit. Close the Security Enclosure door to lock the printer before resuming operation. Refer to Locking and Unlocking the Security Enclosure on page 20. Use the Printer Manager to change settings, and choose a value within the range shown. DO NOT set a security key in the Print Unit. If a security key was set, contact your service provider for assistance. Message 101: Job could not complete Message Source / Text Possible Cause Solution Security Enclosure The card took too long to complete. The card is canceled. Check your card design and send the card again. Page 102 Messages and Error Recovery

113 Message 103: Printer problem Message Source / Text Possible Cause Solution Print Unit: No Card D0 Print Unit: Codes A1, 20, 24, 26, 27, FB, Security Enclosure Security Enclosure Security Enclosure Print Unit problem with handling cards. The printer has a control problem. The printer has a control problem. The card did not reach the Print Unit input area. The message needs to be cleared from the touch screen. Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance. Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance. Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance. Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance. Press the User button to display Ready on the touch screen. Message 104: Critical problem Message Source / Text Possible Cause Solution Print Unit: Hardware 44 Print Unit: Hardware D8 Print Unit: Cam Error C1 Print Unit: HR Overheat C2 Print Unit: Head Overheat F8 Print Unit operation problem. Print Unit operation problem. Cam operation problem. Heat roller operation problem. The thermal head is overheated. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. CR500 Instant Issuance System Installation and User Guide Page 103

114 Print Unit: TR Overheat F0 Print Unit: TR heater F1 Print Unit: TR Thermister F2 Print Unit: RR Overheat F3 Print Unit: RR Heater F4 Print Unit: RR Thermister F5 Print Unit: Power Intrpt C3 Print Unit: Head Overheat F8 Print Unit: EEProm Broken FA Print Unit: MG Mechanical AB Print Unit: MG Hardware AC Security Enclosure The retransfer roller is overheated. Retransfer roller operation problem. Retransfer roller operation problem. Bend Remedy roller operation problem. Bend Remedy roller operation problem. Bend Remedy roller operation problem. Power was interrupted for a short time. The thermal head is overheated. EEPROM malfunction Magnetic stripe mechanical problem Magnetic stripe hardware problem The printer has an internal problem. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Contact your service provider for assistance. Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance. Page 104 Messages and Error Recovery

115 Message 105: Magstripe data error Message Source / Text Possible Cause Solution Security Enclosure Print Unit: MG Test Err OR MG Write Error in Self Test A8 Print Unit: MG Read Error AE Print Unit: MG Write Error AD The printer failed to verify the correct magnetic stripe data was written to the card. A writing error has occurred during magnetic encoder selfdiagnosis. A problem occurred during magnetic encoding data reading. A problem occurred during magnetic encoding data writing. Make sure that you are using magnetic stripe cards that match the printer settings and that the cards are loaded correctly in the hoppers. Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance. Press the User button to clear the message. The card is canceled and moved to the reject area. Check the card specifications and the data sent. Refer to Appendix B, Magnetic Stripe Encoding, for supported formats and characters for each format. Press the User button to clear the message. The card is canceled and moved to the reject area. Check the card specifications and the data sent. Refer to Appendix B, Magnetic Stripe Encoding, for supported formats and characters for each format. Message 106: Magstripe data not found Message Source / Text Possible Cause Solution Security Enclosure The printer did not fine magnetic stripe data on the card. Make sure that you are using magnetic stripe cards that match the printer settings and that the cards are loaded correctly in the hoppers. CR500 Instant Issuance System Installation and User Guide Page 105

116 Message 108: Magstripe read no data Message Source / Text Possible Cause Solution Security Enclosure The printer did not find magnetic stripe data on the card. Make sure that you are using magnetic stripe cards that match the printer settings and that the cards are loaded correctly in the hoppers. Message 111: Card not picked Message Source Possible Cause Solution Security Enclosure A card was picked but did not reach the Print Unit Pick area. Press the User button to clear the message. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 112: Card hopper empty Message Source Possible Cause Solution Security Enclosure Cards are not loaded in the hopper specified by the print job. Load cards. Refer to Load Cards on page 24. Press the User button to clear the message. The card continues processing. After loading cards and clearing the message, if the touch screen shows Busy and you do not hear the card printing, press the User button for 10 seconds to cancel all jobs. Page 106 Messages and Error Recovery

117 Message 113: Close cover to continue Message Source / Text Possible Cause Solution Print Unit: Door Open D1 The Print Unit door is open, or a supply cartridge or cleaning unit is missing. Insert all supply cartridges and the cleaning unit. Initialize printer supplies. Close the Print Unit door and the Security Enclosure door to lock the printer. Press the User button to clear the message. Security Enclosure The Security Enclosure door is open. Close the Security Enclosure door to lock the printer. Press the User button to clear the message. Message 114: Cover opened during job Message Source / Text Possible Cause Solution Security Enclosure The printer was opened during a job. Close the Security Enclosure door to lock the printer. Press the User button to clear the message. Message 115: Wait for print temperature Message Source / Text Possible Cause Solution Security Enclosure CR500 Instant Issuance System Installation and User Guide Page 107

118 Message 116: Magstripe not available Message Source / Text Possible Cause Solution Print Unit: MG Encoder not installed 2D Magnetic encoder is not installed. Press the User button to clear the message. The card is canceled and moved to the reject area. Message 118: Print ribbon type problem Message Source / Text Possible Cause Solution Print Unit: Wrong Ink The ink ribbon requested by the card job is not supported. Press the User button to clear the message. The card is canceled and moved to the reject area. Obtain assistance from the application administrator to match card features, such as Peel-off, with the ink ribbon. Message 119: Print ribbon not supported Message Source / Text Possible Cause Solution Print Unit: Ink Error B0 The ink ribbon installed is not supported. Install a supported ink ribbon. Refer to Ink Ribbon on page 137 for supported ink ribbon part numbers. Press the User button to clear the message. The card is canceled and moved to the reject area. Page 108 Messages and Error Recovery

119 Message 120: User paused the printer Message Source / Text Possible Cause Solution Security Enclosure The user pressed the User button on the touch screen. Press the User Button on the touch screen to unpause the printer. The card continues processing. Message 121: Print ribbon ID problem Message Source / Text Possible Cause Solution Security Enclosure The printer cannot identify the installed ribbon. Use ribbon support by the printer. The card is canceled. Message 122: Magnetic stripe format problem Message Source / Text Possible Cause Solution Print Unit: LCD text unknown Magnetic encoding data is incorrect. Press the User button to clear the message. The card is canceled and moved to the reject area. Check the card specifications and the data sent. Refer to Appendix B, Magnetic Stripe Encoding for supported formats and characters for each format. CR500 Instant Issuance System Installation and User Guide Page 109

120 Message 123: Insert new card side 1 up Message Source / Text Possible Cause Solution Security Enclosure A new card must be inserted in the printer. Insert a new card in the printer with side 1 facing up. Message 124: Insert same card side 1 up Message Source / Text Possible Cause Solution Security Enclosure The same card must be inserted in the printer. Insert the same card with side 1 facing up. Message 149: Option not installed Message Source / Text Possible Cause Solution Print Unit: IC Encoder not installed 2C OR MG Encoder not installed 2D OR Option not installed 2E The smart card encoder or other optional devices are not installed. The magnetic stripe encoder has been removed. Press the User button to clear the message. The card is canceled and moved to the reject area. Do not send cards to the printer unless the options are installed in your printer. Refer to Options in the Printer on page 11. Page 110 Messages and Error Recovery

121 Message 150: Print while unlocked Message Source / Text Possible Cause Solution Security Enclosure The printer is unlocked and a card was sent. Close the Security Enclosure door to lock the printer. Press the User button to clear the message. Message 151: Failed to lock Message Source / Text Possible Cause Solution Security Enclosure The lock command could not complete successfully. Make sure that the Security Enclosure door can close fully, and that the lock pawl is in the vertical position. If needed, use the key to move the lock from the horizontal to vertical position. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. Make sure that nothing interferes with the security and locking features on the door and below the card track. Press the User button to clear the message. Message 152: Insert new card side 2 up Message Source / Text Possible Cause Solution Security Enclosure A new card must be inserted in the printer. Insert a new card with side 2 facing up. CR500 Instant Issuance System Installation and User Guide Page 111

122 Message 153: Insert same card side 2 up Message Source / Text Possible Cause Solution Security Enclosure The same card must be inserted in the printer. Insert the same card in the printer with side 2 facing up. Message 154: Print unit not available Message Source / Text Possible Cause Solution Security Enclosure Print Unit is not found. If the Print Unit is powered on, press the power button to power it off, wait 15 seconds, and power on again. Make sure that the Print Unit is powered on. Press the User button to clear the message. Message 155: Room temperature too low Message Source / Text Possible Cause Solution Print Unit: Overcool F6 It is too cold for the printer to operate. Press the User button to clear the message. The card is canceled and moved to the reject area. Use at the recommended operating environment temperature as described in Operating Environment on page 14. Page 112 Messages and Error Recovery

123 Message 156: Printer warming up Message Source / Text Possible Cause Solution Print Unit: Preheating DA Preheating is in progress. Wait until preheating is complete. This message clears without pressing the User button. Message 157: Input hopper card jam Message Source / Text Possible Cause Solution Security Enclosure Security Enclosure One or more cards were in the card track when the printer was powered on. A card was picked but did not reach the Print Unit. One or more cards were in the card track when a message was cleared with the User button. Press the User button to clear the message. The printer attempts to place the card back in the hopper. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Press the User button to clear the message. Message 158: Check print unit front panel Message Source / Text Possible Cause Solution Print Unit: Please, Power Off The power must be turned off to initialize the printer. Turn the power switch off and then on again. CR500 Instant Issuance System Installation and User Guide Page 113

124 Print Unit: Please Remove Media Cassette Cleaning cannot start when the retransfer film cartridge is in the printer. Remove the retransfer film cartridge. On the Print Unit front panel, press Reset and then Return to initialize the Print Unit. Start the cleaning cycle again, following the steps in Clean the Print Unit on page 84. Print Unit: HR is too hot Cleaning cannot start because the temperature of the heat roller is too high. Power off the printer and allow the heat roller to cool for about 20 minutes. Refer to Clean the Print Unit on page 84 for instructions on how to run the cleaning card. Contact your service provider if HR is too hot displays on the Print Unit front panel and you are not cleaning the printer. Print Unit: Please Adjust Turn Unit Pos! The card turnover unit is not in the correct position. Turn the unit to the home position using a jog dial, as described in Turnover Jam on page 128. Contact your service provider for assistance if the problem persists. Print Unit: Testing or Cleaning DC The Print Unit is processing a cleaning card or the front panel menu is being used. Wait until the cleaning is complete, or complete the menu task. On the Print Unit front panel, press Reset and then Return to initialize the Print Unit. Print Unit: On Setting or Transport Mode DD The Print Unit front panel is being used. Complete any work using the front panel. Close the Print Unit door and then close the Security Enclosure door to lock the printer. The Print Unit has been set to Transport Mode. Power off the printer, wait 15 seconds, and power on to cancel Transport Mode. Print Unit The Print Unit is in power saving mode. Unlock and open the Security Enclosure door. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. On the Print Unit front panel, press Reset and then Return to initialize the Print Unit. Close the doors to lock the printer. Page 114 Messages and Error Recovery

125 Message 159: Print unit card jam Message Source / Text Possible Cause Solution Print Unit: Jam (Hopper) 90 Print Unit: Jam (Turnover) 91 Print Unit: Jam (MG) 92 Print Unit: Jam (Transfer) 93 Print Unit: Jam (Discharge)94 Print Unit: Jam (Retransfer) 95 There is a card jam in the hopper section. There is a card jam in the turnover section. There is a card jam in the magnetic stripe encode section. There is a card jam in the card feed rollers. There is a card jam in the card discharge section. There is a card jam near the retransfer rollers. Remove the jammed card from the card hopper. Refer to Multicard Hopper Jam on page 124 and Print Unit Hopper Jam on page 125. Remove the jammed card from the turnover section. Refer to Turnover Jam on page 128. Remove the jammed card from the turnover section. Refer to Turnover Jam on page 128. Remove the jammed card. Refer to Transfer Jam on page 126. Remove the jammed card. Refer to Transfer Jam on page 126. Check that the concealed card stacker is securely attached to the stacker receptacle. An incorrectly mounted card stacker can cause discharge jams. Remove the jammed card from the retransfer section. Refer to Retransfer Jam on page 130. CR500 Instant Issuance System Installation and User Guide Page 115

126 Message 160: Set print unit to download Message Source / Text Possible Cause Solution Print Unit: Not Ready for Download DE Printer firmware is being updated, and the update includes Print Unit firmware. The printer firmware, including firmware for the Print Unit, is being updated. The Print Unit must be set to accept the firmware. Unlock and open the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for the steps to follow. Using the Print Unit front panel, set the Print Unit to receive the firmware update. Refer to The Print Unit Front Panel Menu System on page 66. Press the User button to clear the message. Message 161: Retransfer film problem Message Source / Text Possible Cause Solution Print Unit: Media Search A1 OR Film Search A1 The retransfer film is broken or missing. Repair the retransfer film as described in Mend a Broken Ink Ribbon or Retransfer Film on page 132. Press the User button to clear the message. Message 162: Retransfer film out Message Source / Text Possible Cause Solution Print Unit: Film Run Out A2 OR Media Run Out A2 Retransfer film is not detected. Retransfer film has run out. Install the retransfer film. Refer to Load Retransfer Film on page 28. Press the User button to clear the message. Page 116 Messages and Error Recovery

127 Message 163: Clear hopper card track Message Source Possible Cause Solution Security Enclosure Security Enclosure A card is in the exception card slot. One or more cards were in the card track when a message was cleared with the User button. Slide out the exception card slide and remove the card. Press the User button to clear the message. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Press the User button to clear the message. Message 164: Ink ribbon problem Message Source / Text Possible Cause Solution Print Unit: Ink Search B1 The ink ribbon is broken. The ink ribbon data is not usable. Repair the ink ribbon as described in Mend a Broken Ink Ribbon or Retransfer Film on page 132. Press the User button to clear the message. Message 165: Ink ribbon out Message Source / Text Possible Cause Solution Print Unit: Ink Run Out B2 Ink ribbon is not detected. The ink ribbon has run out. Install the ink ribbon. Refer to Load Ink Ribbon on page 26. Press the User button to clear the message. CR500 Instant Issuance System Installation and User Guide Page 117

128 Message 169: Move retransfer film one panel Message Source / Text Possible Cause Solution Print Unit The Print Unit needs intervention. Open the printer and move the retransfer film. Refer to step 4 of Print Unit Hopper Jam on page 125 for guidance. Press the User button to clear the message. Message 173: Improper shutdown Message Source / Text Possible Cause Solution Security Enclosure The printer was not shut down correctly, or facility power was interrupted. Press the User button to clear the message. Message 181: Input Hopper Problem Message Source / Text Possible Cause Solution Security Enclosure There is a problem with the firmware or printer settings. Power the printer off and back on. If the message displays again, contact your service provider for assistance. Page 118 Messages and Error Recovery

129 Message 182: Input Hopper Jam two cards Message Source / Text Possible Cause Solution Security Enclosure A card was picked but did not reach the Print Unit. A second card was picked causing two cards to be in the card track. Remove both cards. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 183: Input Hopper jam card lost Message Source / Text Possible Cause Solution Security Enclosure The card did not arrive at the hopper exit. Either the card was not picked, or it was dropped. Remove the card if it was picked. Refer to Multicard Hopper Jam on page 124 for the steps to follow. This could indicate a problem with the rotary or linear offsets. Message 184: Input Hopper jam card at exit Message Source / Text Possible Cause Solution Security Enclosure A card is already at the hopper exit when a new card was to be picked. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. CR500 Instant Issuance System Installation and User Guide Page 119

130 Message 185: Input Hopper jam print input Message Source / Text Possible Cause Solution Security Enclosure A card is already at the entrance of the Print Unit. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 186: Input Hopper Jam at exit Message Source / Text Possible Cause Solution Security Enclosure Security Enclosure A card remained at the multicard hopper exit and did not reach the Print Unit. After a card jam, the card was cleared by pushing it out of the multicard hopper to be deposited in the reject card area. The card was not placed in the reject card area. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 187: Input Hopper Jam print input Message Source / Text Possible Cause Solution Security Enclosure The card still did not reach the Print Unit after an attempt to move it into the Print Unit. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Page 120 Messages and Error Recovery

131 Message 188: Input Hopper Jam print input Message Source / Text Possible Cause Solution Security Enclosure A card is already at the entrance of the Print Unit when another card is to be picked. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 189: Input Hopper jam card at exit Message Source / Text Possible Cause Solution Security Enclosure A card is at the hopper exit during hopper reset. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 190: Input Hopper jam exception Message Source / Text Possible Cause Solution Security Enclosure A card is in the exception slide during a hopper reset. Remove the card from the exception slide. This may or may not require the multicard hopper door to be opened. CR500 Instant Issuance System Installation and User Guide Page 121

132 Message 191: Input Hopper jam print input Message Source / Text Possible Cause Solution Security Enclosure A card is at the entrance of the Print Unit during a hopper reset. Remove the card. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Message 192: Input Hopper Jam exception Message Source / Text Possible Cause Solution Security Enclosure A card is in the exception slide during a hopper reset. Remove the card from the exception slide. This may or may not require the multicard hopper door to be opened. Message 193: MultiHopper Jam two cards Message Source / Text Possible Cause Solution Security Enclosure Two cards were in the card track. After a card jam, an attempt was made to push the card out of the multicard hopper to be deposited in the reject card area. The card at the Print Unit entrance causes the reject to fail. Remove the cards. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Page 122 Messages and Error Recovery

133 Message 194: MultiHopper jam card lost Message Source / Text Possible Cause Solution Security Enclosure A card either was not picked or was dropped before it reached the multihopper exit during a reject operation. Remove the card, if one was picked. Refer to Multicard Hopper Jam on page 124 for the steps to follow. Print Unit Roller Layout Unlock the printer before starting any of the tasks in this chapter. Refer to Locking and Unlocking the Security Enclosure on page 20. After you open the Security Enclosure, you can open the Print Unit door to access the Print Unit cartridges and rollers. CR500 Instant Issuance System Installation and User Guide Page 123

134 Printer Error Recovery The printer touch screen displays messages. The Print Unit front panel background color changes to red when the Print Unit has an problem, and it displays text that describes the problem. Multicard Hopper Jam If a card jams in the multicard hopper: 1. Press the User button on the touch screen to attempt to clear the problem. If the card jam message displays again, continue with these steps. 2. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 3. Open the Security Enclosure door. 4. Try the following in the order presented: a. Look at the multicard hopper, near the Print Unit pick roller, for jammed cards. i. If you can reach the jammed card, pull it out (A). ii. If needed, remove the backup roller (B) to make it easier to pull the card out. Replace the backup roller when the card is removed. b. For cards in the middle of the card track, work the card back to the exception card slide (C), and then extend the slide and remove the card. 5. Record the type of card removed (from hopper 1, 2, 3 or the exception card slide), following your organization s guidelines for tracking cards and supplies. 6. On the Print Unit front panel, look for a message. Card Out is the expected message. If another message displays, refer to Message 158: Check print unit front panel on page 113 for the message. Page 124 Messages and Error Recovery

135 7. Close the Security Enclosure door to lock the printer. 8. On the touch screen, press the User button to clear the problem and reset the printer. The touch screen shows Busy while the printer initializes. Print Unit Hopper Jam If a card jams in the input area or cleaning roller area of the Print Unit: 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. Read the Print Unit front panel to verify the location of the jam. a. Power off the printer and open the Print Unit door. b. Remove the card if you can. c. If you could not remove the card, place a jog dial on the lower shaft of the cleaning unit. d. Turn the jog dial clockwise to move the card until you can see it in the hopper. e. Remove the card and return the jog dial to the home location. CR500 Instant Issuance System Installation and User Guide Page 125

136 4. Remove the Retransfer Film cartridge. If a printed image displays on the vertical or horizontal area, turn the take up knob (E) to advance the film (D). All printed areas should be on the take up spool (B). Transfer Jam 5. Replace the cartridge. 6. Close the Print Unit door. Press Reset and then Enter on the Print Unit front panel. 7. Close the Security Enclosure door to lock the printer. 8. On the touch screen, press the User button to clear the problem and reset the printer. The touch screen shows Busy while the printer initializes. If the card jams in the card feed rollers, the Jam (Transfer) message displays on the Print Unit front panel. Use the following procedure to remove the jammed card. Caution: Some internal parts may be hot. Wear a glove when reaching into the printer or let it cool first. If a card jams in the input areas of the Print Unit: 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. Read the Print Unit front panel to verify the location of the jam. a. Power off the printer and open the Print Unit door. b. Locate the jammed card. Page 126 Messages and Error Recovery

137 c. Place one jog dial on the cleaning unit shaft and the other jog dial on the card feed rollers shaft. d. Turn both shafts clockwise to move the card toward the hopper area. Do not force the card to move. Contact your service provider for assistance if the card does not move easily. e. Remove the card from the hopper area or the reject card outlet. f. If the printer has a turnover unit, make sure it is horizontal, in the home position. Refer to Turnover Jam on page 128. g. Return the jog dial(s) to the home location. 4. Remove the Retransfer Film cartridge. If a printed image displays on the vertical or horizontal area, turn the take up knob (E) to advance the film (D). All printed areas should be on the take up spool (B). CR500 Instant Issuance System Installation and User Guide Page 127

138 Turnover Jam 5. Replace the cartridge. 6. Close the Print Unit door. Press Reset and then Enter on the Print Unit front panel. 7. Close the Security Enclosure door to lock the printer. 8. On the touch screen, press the User button to clear the problem and reset the printer. The touch screen shows Busy while the printer initializes. If a card jams in the card turnover section, the Jam (TurnOver) message displays on the Print Unit front panel. Use the following procedure to remove the jammed card. Caution: Some internal parts may be hot. Wear a glove when reaching into the printer or let it cool first. 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. Read the Print Unit front panel to verify the location of the jam. a. Power off the printer and open the Print Unit door. b. Remove the cleaning unit as described in Clean the Card Cleaning Rollers and Cleaning Unit on page 80. c. Locate the jammed card. d. Remove the jammed card from the turnover unit through the slot in the input area. If you cannot remove the card, skip to step 4. e. Replace the cleaning unit. f. Place a jog dial on the turnover unit shaft. Page 128 Messages and Error Recovery

139 g. Turn the jog dial until the turnover unit is horizontal and the bar on the dial points to the right. This is the home position for the turnover unit. Continue with step Do this step only if you could not remove the card through the input slot: a. Replace the cleaning unit. b. Place a jog dial on the turnover unit shaft. c. Place the second jog dial on the lower cleaning unit shaft. d. Turn both the turnover unit and the cleaning roller shaft and set the turnover unit to the home position. The card should remain in, or move into, the turnover unit. e. Make sure that the turnover unit is horizontal, in home position. f. Turn the cleaning roller shaft clockwise to move the card into the input slot and remove the card. Do not force the card to move. If the card does not move easily, contact your service provider for assistance. 5. Return the jog dial(s) to the storage location. CR500 Instant Issuance System Installation and User Guide Page 129

140 6. Remove the Retransfer Film cartridge. If a printed image displays on the vertical or horizontal area, turn the take up knob (E) to advance the film (D). All printed areas should be on the take up spool (B). Retransfer Jam 7. Replace the cartridges. 8. Close the Print Unit door. Press Reset and then Enter on the Print Unit front panel. 9. Close the Security Enclosure door to lock the printer. 10. On the touch screen, press the User button to clear the problem and reset the printer. The touch screen shows Busy while the printer initializes. If a card jams in the retransfer section, the Jam (Retransfer) message displays. Use the following procedure to remove the jammed card. Caution: Some internal parts may be hot and the card may be very hot. Wear a glove when reaching into the printer or let it cool first, and use the supplied tweezers to remove the card. 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. Read the Print Unit front panel to verify the location of the jam. a. Power off the printer and open the Print Unit door. b. Press the retransfer film cartridge eject button and remove the retransfer film cartridge. Caution: The card might be stuck to the film. Watch carefully to avoid jamming the card when removing the retransfer film cartridge. Page 130 Messages and Error Recovery

141 If Please Close Door displays, the retransfer film cartridge is stuck. Push it back into the printer, close the door, and return to step 3. c. Remove the card from the printer or from the retransfer film cartridge. d. If the card is stuck to the right of the heat roller, Refer to Transfer Jam on page 126. e. If the card is stuck near the Retransfer heat roller, use the supplied tweezers to slowly remove the card, as shown at the right in the above figure. 4. Look at the retransfer film. If a printed image displays on the vertical or horizontal area, turn the take up knob (E) to advance the film (D). All printed areas should be on the take up spool (B). 5. Replace the cartridge. 6. Close the Print Unit door. 7. Power on the printer. CR500 Instant Issuance System Installation and User Guide Page 131

142 8. Press Reset. The Card Jam Removed? message displays on the Print Unit front panel. Press Yes if the card has been removed. Do not initialize the printer with the card still inside. Press No if the card remains inside the printer and contact your service provider for assistance. 9. Close the Security Enclosure door to lock the printer. 10. On the touch screen, press the User button to clear the problem and reset the printer. The touch screen shows Busy while the printer initializes. Mend a Broken Ink Ribbon or Retransfer Film If the ink ribbon or retransfer film breaks, the Ink Search or Media Search message displays on the Print Unit front panel. The following example shows a broken ink ribbon; fix broken retransfer film using the same steps. 1. Unlock the printer. Refer to Locking and Unlocking the Security Enclosure on page 20 for steps to follow. 2. Open the Security Enclosure door. 3. Read the Print Unit front panel to verify the problem. 4. Power off the printer, and open the Print Unit door. 5. Press the eject button for the appropriate cartridge, and remove the cartridge. 6. Trim the ends of the broken ribbon or film evenly. Do not remove the used ink ribbon or film from the take up spool. 7. Align the ends of the broken media and apply tape to secure them. Page 132 Messages and Error Recovery

143 8. Turn the take up spool counterclockwise until the mended portion is wound onto the spool two or three turns. Take-up Spool Tape 9. For ink ribbon, make sure the yellow panel aligns with the arrow on the cartridge. 10. Reinstall the cartridge into the Print Unit until it clicks into position. 11. Close the Print Unit door. Press Reset and then Enter on the Print Unit front panel. 12. Close the Security Enclosure door to lock the printer. 13. On the touch screen, press the User button to clear the problem and reset the printer. The touch screen shows Busy while the printer initializes. CR500 Instant Issuance System Installation and User Guide Page 133

144 Page 134 Messages and Error Recovery

145 Chapter 9: Supplies This chapter outlines the recommended supplies to use with the Datacard CR500 card printer. Storage Environment for Supplies on page 136 Ink Ribbon and Retransfer Film on page 137 Cards on page 138 Cleaning Supplies on page 139 Replacement Parts on page 139 CR500 Instant Issuance System Installation and User Guide Page 135

146 Storage Environment for Supplies Follow these guidelines for storing supply rolls: Store supplies in their original packaging until you are ready to use them. Choose a location away from direct sunlight, with a temperature between 41 and 77 F (5 and 25 C) with a maximum of 40 to 60% relative humidity. Do not store supplies in high humidity locations. The print ribbon maintains its quality for about one year. For optimal card quality, only purchase and store quantities that you can use up in less than a year. The print ribbon and card stock might require secure storage and tracking. Follow your policy for storing and tracking the supplies used to make cards. Supply rolls should be at room temperature when they are installed in the printer and used. If supplies are stored in a cooler environment, allow them to reach room temperature before using. If the printer will not be used for an extended period of time, remove supplies from the printer and store them in their original package. When choosing a site for the printer and its supplies, consider these guidelines: Place the printer in a clean office environment, protected from any type of construction. Avoid locating the equipment and supplies in dirty or dusty environments, near heating ducts or blowers, in areas susceptible to strong vibration or shock, or in direct sunlight. Keep all dust, dirt, food, liquids, etc. away from the printer. Place the printer on a stable platform; keep it off the floor. Store all supplies in a clean, cool, and dry location and in the original packaging until you load them in the printer. Keep the original packaging closed. Page 136 Supplies

147 Ink Ribbon and Retransfer Film Ink Ribbon Color print ribbons are designed for full color card printing. The ribbons use the following color panels: Y=yellow, M=magenta, C=cyan, and K=black. The following ink ribbon is available: Type Part Number Maximum Cards/Roll Purpose YMCK-I (or YMCK-PO) Full color with a non-printing (peel-off) area on one or both sides. Retransfer Film The following retransfer film is available: (Prints up to 1000 single sided cards.) CR500 Instant Issuance System Installation and User Guide Page 137

148 Cards Card Size This section describes specifications and quality guidelines for card stock to use with the CR500 printer. For best results, use high quality card stock that meets the specifications and recommendations described in this section. Card production success depends on the card manufacturer and card construction. Cards are available the meet the requirements listed in this section, but that might not perform as you expect. Use cards that conform to the following specifications: ISO/IEC 7810 Type ID 1 ISO/IEC Magnetic stripe (optional) ISO/IEC 7816 Smart card (optional) Specification ISO/IEC 7810 includes a requirement that cards have an optical density of 1.5 or greater. Contact your service provider before using a preprinted magnetic stripe card or smart card. Dark color preprinted cards can cause positioning errors during encoding. Use ISO 1 (CR 80) size cards with the following nominal dimensions: Length inches 85.6 mm Width inches 54 mm Thickness inch 0.75 mm Card Material For best results, use cards made from one of the following materials: PVC PET PET G Polycarbonates ABS Page 138 Supplies

149 Cleaning Supplies The printer needs the following cleaning supplies. For best results, keep cleaning supplies on hand. Type Cleaning cards Dual-sided cleaning cards Printhead cleaning swabs Magnetic head cleaning cards Part Number , pack of 10 cards , pack of 10 cards , pack of 5 swabs , pack of 10 cards Cleaning roller unit Printer fan filter White glove Replacement Parts The following replacement parts are available: Power Supply Card Weight Power Cords Contact your local service provider for the correct power cord for your location. CR500 Instant Issuance System Installation and User Guide Page 139

150 Page 140 Supplies

151 Chapter 10: Using Printer Manager This chapter describes how to perform management tasks required to operate the Datacard CR500 printer. Start and Stop Printer Manager on page 142 Printer Manager Settings on page 144 Status Menu on page 145 Printer Setting Menu on page 147 Troubleshooting Menu on page 162 Maintenance Menu on page 165 Printer Manager Updates on page 165 CR500 Instant Issuance System Installation and User Guide Page 141

152 Start and Stop Printer Manager The printer includes Printer Manager, a web based interface that displays information about the printer and provides setup and troubleshooting tools. Printer Manager is available through a web browser. Supported web browsers include Internet Explorer v7 or higher and Firefox v3.6 or higher. Start Printer Manager During normal operation, site personnel should not use Printer Manager unless asked to do so. 1. Get the printer IP address. Refer to Retrieve the Printer IP Address on page Open a web browser on the PC. 3. In the Address area of the browser, type the following: For example: where represents the printer IP address. 4. Press the Enter key. The web browser might display a certificate message because the current printer IP address is different from the IP address on the certificate. Click Continue to this website to use Printer Manager. 5. In the Printer Manager Please Log In area, select a Username and enter a password, if one is required. Page 142 Using Printer Manager

153 The default Username is WebUser. WebUser level users can view Status information. No password typically is required. WebAdmin users can print a test card and make some settings changes. For printer setup, choose WebAdmin. A password may be required. WebAdmin level users can create or change the passwords for WebAdmin and WebUser. WebService users have additional access for settings and troubleshooting. A password is required. WebService level users can create or change the passwords for WebService, WebAdmin, and WebUser. 6. Click Log In. 7. The Printer Manager Welcome page displays. Hints & Tips The access level controls the information that displays and the changes that can be made. If the browser cannot connect to the printer, make sure: Stop Printer Manager The printer display shows Ready. Another user does not have a Printer Manager session running. A VPN (Virtual Private Network) client is not restricting your access to Printer Manager. Log out of the VPN client and reconnect to your local network, if needed. Select Log Out from the menu to end the current Printer Manager session. For security, close the browser window after logging out. CR500 Instant Issuance System Installation and User Guide Page 143

154 Printer Manager Settings The CR500 printer is shipped with recommended settings in Printer Manager. You may need to change these settings to customize the printer for your site. Printer Manager provides access to the printer settings. Many of the Printer Manager menu options display the Set Current and Restore Default buttons. Set Current saves any changed settings on the displayed page. When you change a value and click Set Current, the printer uses the new settings until the default values are restored. Restore Default restores the factory default settings to the values on the displayed page. The following sections explain the Printer Manager menus and the adjustments that you can make. Options with an (A) in the Printer Manager tables in the following sections are available only when logged in using the WebAdmin access level. Options without an (A) also are available to WebUser access level users. Page 144 Using Printer Manager

155 Status Menu The Status menu options display basic information about the printer and its status. The Status menu is display only and cannot be changed. Menu Option Description Purpose VPD Printer Status 1. Manufacturer 2. Model 3. Agency Model 4. Options Installed 5. Serializations 6. Versions 1. Printer State 2. Seconds On 3. Current Conditions 4. Job Status Displays vital product data (VPD) information, including the manufacturer, model, options, and version information. Displays printer status information including the state, how long the printer has been on (in seconds), the current conditions of the printer, and recent job status. CR500 Instant Issuance System Installation and User Guide Page 145

156 Menu Option Description Purpose Supplies Audit Data 1. Ribbon Part Number 2. Ribbon Lot Code 3. Ribbon Remaining 4. Ribbon Max Length 5. Ribbon Serial Number 6. Ribbon Module 7. Ribbon Supported 8. Ribbon Action Sequence 9. Ribbon Supply Code 10. Ribbon Special Code 11. Ribbon Region Code 12. Ribbon Product Code 1. CardsPickedInputHopper1 2. CardsPickedInputHopper2 3. CardsPickedInputHopper3 4. CardsPickedInputHopper Exception 5. GoodCards 6. LostCards 7. PrinterStartupCount 8. PrintJobCancels 9. PrintJobRecoveryAttempts 10. PrintJobRestarts 11. PrintJobResumes 12. PrintJobsFailed 13. PrintJobsReceived 14. PrintJobsRun 15. PrintJobsSucceeded Resettable counters 31. SameCardSecond SidePicks Displays detailed ribbon information including the type of ribbon; identifying information, such as part number; and percentage of ribbon remaining. The information displays for each ribbon module, such as retransfer film and ink ribbon. Displays detailed card printer usage data. Entries with an r as the first letter of the name are resettable counters. About Printer Manager Displays the Printer Manager software version and copyright information. Page 146 Using Printer Manager

157 Printer Setting Menu The Printer Setting menu allows you to view and change printer settings. Menu Option Description Purpose Communication (A) ActivityLog (A) 1. EthAddressMethod 2. EthDnsAddress1 3. EthDnsAddress2 4. EthDnsSearchSuffix 5. EthGatewayAddress 6. EthIpAddress 7. EthSubnetMask 1. ExternalLog 2. ExternalLogServer 3. FilterCardActions 4. FilterConfigChanges 5. FilterJobStates 6. FilterSoapMsgs 7. FilterSystem 8. InternalLog Displays the default and current values of the communication method DHCP (dynamic) or STATIC and address information. Changes the current information or restores the default values. Refer to Communication on page 150 for more information on setting these values. Allows you to enable or disable the internal and external logs and designate the external log server IP address. The activity log filters specify the severity level required to write information to the log, or turn off the filter. The filter severity levels include: Critical, Error, Warning, Notice, Information, Debug, and Disabled. Use this option to change the current values or restore the default values. Refer to ActivityLog Example on page 152 for an example of using the Activity Log. CR500 Instant Issuance System Installation and User Guide Page 147

158 Menu Option Description Purpose Behavior (A) 1. ActivityLogExternal 2. ActivityLogInternal 3. DPCL 4. DPCL2 5. DPCL2Secure 6. DPCLSecure 7. Remake 8. RemakeMethod 9. RetrieveDataTimeout 10. PowerSaverMode 11. WebServerSecure Displays the default and current status of printer operation and control methods. Use to change the current information or restore the default values. Refer to Behavior on page 153 for more information on specifying Behavior settings. Caution: Do not change the WebServerSecure option. If the web server is disabled, the printer is unable to receive communications. VitalProductData Available to WebService access level users only. FrontPanel (A) Print (A) 1. LcdConfigMenu 2. LedRibbonLow 1. SettingsGroupPurpose 2. ApplyBendRemedy 3. BacksideCooling 4. BendRemedyRetransfer RollerTemp 5. KPower 6. OffsetCardX 7. OffsetPrtX 8. OffsetPrtY 9. OffsetTrfX 10. PeelOffPower 11. ResinBlackMode 12. RetranferRollerTemp 13. YMCPower Displays the default, current values, and allowed ranges for the front panel options. Use to change the current information or restore the default values. Refer to FrontPanel on page 154 for more information. Displays the default, current values, and allowed ranges for the print options. Use to change the current information or restore the default values. Refer to Print Settings on page 155 for more information on the Print options. Some items may not be available in the printer. Page 148 Using Printer Manager

159 Menu Option Description Purpose Pick (A) MagStripeGeneral (A) 1. ExceptionLinearOffset 2. ExceptionRotationOffset 3. Hopper1LinearOffset 4. Hopper1RotationOffset 5. Hopper2LinearOffset 6. Hopper2RotationOffset 7. Hopper3LinearOffset 8. Hopper3RotationOffset 1. Coercivity 2. ISOHICOMode 3. Track1Format 4. Track2Format 5. Track3Format 6. RetryCount Displays the default, current values, and allowed ranges for picking cards from the exception slot and multicard hopper and the movement of cards into the printer. Use the settings to change the current information or restore the default values. Refer to Pick Settings on page 160 for more information. Displays the default, current values, and limits for general magnetic stripe options. Use to change the current information or restore the default values. Refer to MagStripeGeneral on page 161 for more information. Update Password (A) Allows you to set, update, and confirm a new password for the Printer Manager access usernames. SetJobQueue State CurrentPassword NextPassword ConfirmNextPassword State: Online, Suspended or Offline Use to secure the printer when performing troubleshooting, maintenance, and other procedures. Select a state from the following: Online: The printer performs normally. Suspended: Deactivates the printer but allows some exception jobs to start. Offline: Disables the job queue to secure the printer before transporting it. To re-enable an Offline printer and set it back to Online, you must enter the same password that was used to set it to Offline. CR500 Instant Issuance System Installation and User Guide Page 149

160 Communication Use the Printer Setting menu Communication options to specify the Ethernet address method used by the printer. Option EthAddressMethod EthDnsAddress1 EthDnsAddress2 Description Specify the communication method used by the printer. Options are DHCP and STATIC. DNS server information. EthDnsSearchSuffix EthGatewayAddress EthIpAddress EthSubnetMask If EthAddressMethod is STATIC, enter the gateway address for the network. If EthAddressMethod is DHCP, the DNS server controls this setting. If EthAddressMethod is STATIC, enter the IP address for the network. If EthAddressMethod is DHCP, the DNS server controls this setting. If EthAddressMethod is STATIC, enter the subnet mask for the network. If EthAddressMethod is DHCP, the DNS server controls this setting. Page 150 Using Printer Manager

161 ActivityLog Use the Printer Setting menu ActivityLog options to enable or disable an internal or external activity log. When you specify an external log server, you can send the activity log to a syslog server monitored by a third party application. You specify the types of actions to include in the logs and set the severity level for when the action should be written to the log. Filter severity level options are: Critical, Error, Warning, Notice, Information, Debug, and Disabled. Option ExternalLog ExternalLogServer FilterCardActions FilterConfigChanges FilterJobStates FilterSoapMsgs FilterSystem InternalLog Description Enable or disable writing the Activity Log to an external Syslog server. Specify the IP Address of the external syslog server, if ExternalLog is set to Enabled. Write the start and completion of a card action with the specified severity, and higher, to the activity log. Default: Notice Write configuration change actions with the specified severity, and higher, to the activity log. Default: Notice Write changes to the state of a print or exception job with the specified severity, and higher, to the activity log. Default: Notice Write DPCL/Soap (Simple Object Access Protocol) messages from the printer with the specified severity, and higher, to the activity log. Default: Notice Write system information with the specified severity, and higher, to the activity log. A value of Information results in most events being written to the log. Default: Notice Enable or disable the Activity Log on the printer. Default: Enabled CR500 Instant Issuance System Installation and User Guide Page 151

162 ActivityLog Example The following example shows how to monitor the job state status to help troubleshoot a card production problem. 1. Select ActivityLog from the Printer Setting menu. 2. Set FilterJobStates to Error. 3. Click Set Current to save your changes. Changes to the state of a job with this severity, or higher, will be written to the activity log. Page 152 Using Printer Manager

163 Behavior Use the Printer Setting menu Behavior options to control the printer operation. Option ActivityLogExternal ActivityLogInternal DPCL DPCL2 DPCL2Secure DPCLSecure Remake RemakeMethod RetrieveDataTimeout Description Enable or disable writing the activity log to an external syslog server. Default: Enabled Enable or disable the internal activity log. Default: Enabled Enable or disable DPCL command access to the printer through the unsecured port. Default: Enabled Enable or disable DPCL2 command access to the printer through the unsecured port. Default: Enabled Enable or disable DPCL2 command access to the printer through the secure port. Default: Enabled Enable or disable DPCL command access to the printer through the secure port. Default: Enabled Enable or disable card remakes. If Remake is enabled and a print request fails, the print request is tried again with a new card. A card is retried only once. Default: Enabled Select the card remake method. Choices are PreserveOrder (reprint in queue order) or ConserveSupplies (reprint out of queue order). This setting is ignored if Remake is set to Disabled. Default: ConserveSupplies Specify the time period during which card data can be retrieved. You can specify from 0 to 120 seconds. If the current value is 0, data is not retrieved. CR500 Instant Issuance System Installation and User Guide Page 153

164 Option PowerSaverMode WebServerSecure Description Power off the retransfer roller in the Print Unit after the specified number of minutes of no activity. Power off requires a warm up period before the printer is ready to print cards again. A value of Off keeps the retransfer roller heated whenever the printer is on. However, keeping the roller on can keep supplies very warm. Range: Off, 5, 30, 60 Default: 30 minutes Allow access to Printer Manager (the web server) through the secure port. Default: Enabled Caution: Do not disable the web server. If the web server is disabled, the printer cannot receive communications. To reverse this action, you must contact Datacard for a DPCL application. FrontPanel Use the Printer Setting menu FrontPanel options to customize the printer LCD touch screen. Option LcdConfigMenu LedRibbonLow Description Enable or disable the Configuration menu display on the LCD touch screen. Default: Enabled The Status and Maintenance menus cannot be disabled. Set the percentage of ribbon remaining before being notified that the ribbon is low and should be changed. Range: 0 to Default: 10 percent Page 154 Using Printer Manager

165 Print Settings Use the Printer Setting menu Print options to control the quality of the printing. Option SettingsGroupPurpose ApplyBendRemedy BacksideCooling BendRemedyRetransfer RollerTemp Description Describes the purpose of a settings group. Use it to state the reason for creating a settings group. Enable or disable the bend remedy. Caution: Do not enable if you are using smart cards. Default: Disabled Enable the bend remedy if completed cards are bowed. The card type material can affect the amount of bowing. Allows the card to cool between transferring the image to the front side of the card and the back side of the card. This setting is valid only during double-sided printing. Default: Disabled Enable BacksideCooling if cards are warped as they are ejected. Disable BacksideCooling to improve print speed. Increase or decrease the temperature of the bend remedy roller. Range: 5 to 0 special units Default: 0 special units Increase the temperature value if using the bend remedy results in concave cards. Decrease the temperature value if using the bend remedy results in convex cards. Determine the BendRemedyRetransferRollerTemp value to use based on the card type material and the BendRemedyVelocity. (Bend remedy velocity is a WebService setting. Contact your service provider for assistance.) Print sample cards to determine the appropriate settings for your card type. CR500 Instant Issuance System Installation and User Guide Page 155

166 Option KPower Description Increase or decrease print intensity for the K panel of the ink ribbon. This adjustment controls the overall lightness or darkness of the K panel. Range: 3 to +3 special units Default: 0 special units Increase KPower to make monochrome printing more intense. Decrease KPower to reduce intensity (for crisp bar codes) or to prevent ribbon breaks while printing the K panel. Example: The first card has the KPower set too low, resulting in voids in the bar code. The second card may have the KPower set too high. To determine to best setting, adjust the KPower is to reduce the power until there are voids in the bar code. Then, increase the KPower until they just fill in. The printing may look a little light to the eye, but this provides the best results for a bar code reader. OffsetCardX Sets the stop position of the card and changes the retransfer start position. Use this setting only if cards do not meet the ID-1 specification. Range: 7 to +7 special units (each unit moves the card about 0.17 mm.) Default: 0 special units Page 156 Using Printer Manager

167 Option OffsetPrtX OffsetPrtY Description Sets the position of printing on the card in the short direction. Range: 7 to +7 special units (each unit moves the card about mm.) Default: 0 special units If the image is not centered on the card in the short direction, contact your service provider for assistance to change this setting. Sets the position of printing on the card in the long direction. LEFT X B=2.07mm RIGHT BACK R A=2.15mm Y G FRONT B Card shifting direction Printing start Range: 15 to +15 special units (each unit moves the card about 0.17 mm.) Default: 0 special units If the image is not centered on the card in the long direction, contact your service provider for assistance to change this setting. CR500 Instant Issuance System Installation and User Guide Page 157

168 Option OffsetTrfX Description Sets the position of retransfer printing on the card in the long direction. LEFT X B=2.07mm RIGHT BACK R A=2.15mm Y G FRONT B Card shifting direction Printing start Range: 14 to +14 special units (each unit moves the card about mm.) Default: 0 special units If the image is not centered on the card in the long direction, contact your service provider for assistance to change this setting. PeelOffPower ResinBlackMode Changes the intensity of printing for the Peel-off ribbon panel. This adjustment controls the overall strength of Peel-off. Range: 3 to +3 special units Default: 0 Decrease the PeelOffPower value to reduce wrinkling on the Peel-off panel or to prevent ribbon breaks when you use a Peeloff ribbon. Enable or disable to modify printing of the black (K) panel. Default: Disabled Enable ResinBlackMode to improve print quality if thin lines or small black text is blurred. This slows the print speed. Disable ResinBlackMode to improve print speed when fine black printing is not used. Page 158 Using Printer Manager

169 Option RetransferRollerTemp YMCPower Description Increases or decreases the temperature of the retransfer roller. Range: 2 to +2 special units Default: 0 special units Increase this setting if using the bend remedy results in concave cards. Decrease the setting to reduce wrinkling of the retransfer film or to prevent film breaks while retransferring the image to the card. Determine the retransfer roller temperature to use based on the type of card material and the retransfer velocity. (Retransfer velocity is a WebService setting. Contact your service provider for assistance.) Print sample cards to determine the appropriate settings for your card type. Changes the intensity of printing for the Y, M, and C ribbon panels. This adjustment controls the overall lightness or darkness of the YMC panels. Range: 3 to +3 special units Default: 0 special units Increase the YMCPower to make color printing more intense. Decrease the YMCPower to reduce intensity or to prevent ribbon breaks while printing colors. CR500 Instant Issuance System Installation and User Guide Page 159

170 Pick Settings The Pick settings control the pick motor and time frames for picking cards. These adjustments are all related to feeding a card into the printer. Option ExceptionLinearOffset ExceptionRotationOffset Description Sets the linear offset to pick a card from the Exception Card Slide. Range: 500 to 500 steps Default: 0 Sets the rotational movement offset to pick a card from the Exception Card Slide. Range: 10 to 10 steps Default: 0 Hopper1LinearOffset Sets the linear offset to pick a card from hopper 1. Range: 500 to 500 steps Default: 0 Hopper1RotationOffset Sets the rotational movement offset to pick a card from hopper 1. Range: 10 to 10 steps Default: 0 Hopper2LinearOffset Sets the linear offset to pick a card from hopper 2. Range: 500 to 500 steps Default: 0 Hopper2RotationOffset Sets the rotational movement offset to pick a card from hopper 2. Range: 10 to 10 steps Default: 0 Hopper3LinearOffset Sets the linear offset to pick a card from hopper 3. Range: 500 to 500 steps Default: 0 Hopper3RotationOffset Sets the rotational movement offset to pick a card from hopper 3. Range: 10 to 10 steps Default: 0 Page 160 Using Printer Manager

171 MagStripeGeneral Magnetic stripe settings are available for WebAdmin and WebService access level users to set up basic magnetic stripe options. Option Coercivity ISOHICOMode Description Select the coercivity setting that matches the cards you are using. Coercivity measures the resistance of magnetic material to the removal of encoded data. High coercivity (HICO) requires more electrical force to encode data and the data is more resistant to magnetic interference. Range: HICO, LOCO Default: HICO Select the HICO mode for the magnetic stripe. Range: Standard, Super Default: Standard Track1Format Specify the data format for track 1. Range: None not used 6unit alphanumeric, 76 characters 7unit alphanumeric, 69 characters AAMVA6unit AAMVA, 79 characters JIS2 JIS2, 7 unit code, 69 characters Default: 6unit Track2Format Specify the data format for track 2. Range: None not used 4unit numeric, 37 characters Default: 4unit CR500 Instant Issuance System Installation and User Guide Page 161

172 Option Description Track3Format Specify the data format for track 3. Range: None not used 4unit numeric 104 characters 7unit alphanumeric, 69 characters AAMVA6unit AAMVA, 79 characters Default: 4unit RetryCount Specify the number of attempts (automatic retries) the printer makes to encode (and read) the magnetic stripe data. Range: 0 to 3 Default: 2 Troubleshooting Menu The options on the Troubleshooting menu allow you to print test cards, manage the audit log, and reset card counts. Page 162 Using Printer Manager

173 Menu Option Description Purpose Test Card (A) 1. Input Hopper Number 2. Magnetic Stripe 3. Color 4. Monochrome 5. Test Pattern to use for Color and/or Monochrome 6. Copies 7. Park Smart Card 8. Park Position 9. Smart Card Park Time 10. Do not eject card Select the options to print one or more test cards. Refer to Test Card on page 163 for more information. Activity Log (A) Reset Log (A) Reset Counters (A) Printer Reset (A) Download the activity log information and save it to a text file. Click Download (scroll to the bottom of the window) to save the file. Reset the log. Click Run in the Reset Log submenu to remove all of the entries from the Activity Log. Reset the Current Count counters in the printer. Click Run in the Reset Counters submenu to reset the counters. Life counters or total card counts cannot be reset. Reset the card printer. Click Run in the Printer Reset submenu to perform a cold restart on the printer. This is the same as powering the printer off and on again. After the printer has reset, you can resume using Printer Manager without logging in again. Test Card Use the TroubleShooting menu Test Card options to identify card production issues. When printing test cards, make sure to keep track of the cards printed and their source. Due to the requirements of the financial card market, each card printed must be accounted for. Use your own blank cards to preserve the pre printed customer card stock. Also provide counts of test cards and supplies for customer tracking. Option Input Hopper Number Magnetic Stripe Description Select the input hopper number where the test card to be used is loaded. Print the card with encoded magnetic stripe data. CR500 Instant Issuance System Installation and User Guide Page 163

174 Option Color Monochrome Test Pattern to use for Color and/or Monochrome Description Print the test card using the YMCK panels of the print ribbon on the front or back. Print the test card using a monochrome ribbon (or the K panel of a color ribbon) on the front or back. Select a test pattern to use on the front or back of the test card, from the following: TestPattern1: Full color test card used to evaluate overall print quality using the YMCK panels of the print ribbon. TestPattern2: Half color test card used to evaluate overall print quality when using short-panel YMCKT ribbon. TestPattern3: Dense blue test card to test intensity issues that can appear as wrinkles on the printed card. TestPattern4: Color step test card (RGBK/YMC) that uses all panels of the print ribbon and displays the steps of each color from darkest to lightest. TestPattern5: Used to set up card registration. TestPattern6: Prints a marbles-image test card to evaluate general appearance. TestPatternCheckered and TestPatternRegistration: Used to check card registration mechanically. Side/side or lead/trailing issues may indicate a chassis, card guide, or roller problem. TestPatternGrid: Used to print a full K panel test card. TestPatternManufactureA E: Used only during manufacturing setup. Copies Enter the number of test cards to print for each test, from 1 to 10. Default: 1 Park Smart Card Park Position Smart Card Park Time Do not eject card Parks the test card in the smart card bay. The test does not transmit any data, but is used to test the movement of the card into, and out of, the bay. Select the smart card park position from the following: ContactSmartCard or ContactlessSmartCard. Enter the amount of time to hold the test card in the smart card bay, from 0 to 300 seconds. Default: 10 seconds Select this option to prevent the test card from being ejected from the printer. Page 164 Using Printer Manager

175 Maintenance Menu Use the Maintenance menu to upload Printer Manager settings following a repair. You must have WebService level access to Printer Manager to download the settings prior to the repair. Menu Item Updates (A) Description Use this option to browse to an external settings file and upload it to the printer. (You must be signed on with WebService-level access to download the printer settings used by Printer Manager. Contact your service provider for assistance.) 1. Click Browse and select the file to upload. 2. Click Upload File. Printer Manager Updates Printer Manager updates are included with firmware updates. A separate stand alone utility, the Card Printer Firmware Update Utility Program, is used to update the printer firmware. The update utility is available as a separate download on the Datacard website. CR500 Instant Issuance System Installation and User Guide Page 165

176 Page 166 Using Printer Manager

177 Appendix A: Printer Specification This chapter describes the operating environment recommended for your Datacard CR500 card printer. General Printer Specifications on page A 2 Operating Environment Conditions on page A 2 Storage Environment Conditions on page A 2 CR500 Instant Issuance System Installation and User Guide Page A-1

178 General Printer Specifications Recording method: Feed format: Recording density: Reproduction gradations: Printing time: Interface: Dye Sublimation Retransfer Automatic feed 300 dpi 256 levels each Yellow (Y), Magenta (M), and Cyan (C); 2 for Black (K) 29 seconds (single-sided, excluding data transfer time) Ethernet (100Base-Tx or 10Base-T) Operating Environment Conditions Temperature: Humidity: Using YMCK panels only: 59 F to 86 F (15 C to 30 C) Using Peel-off panels: 63 F to 83 F (17 C to 28 C) 35% to 70% (non-condensing) 35% to 60% if using Peel-off ribbon Storage Environment Conditions Temperature: 5 F to 131 F (-15 C to 55 C) Humidity: 20 to 80% Power supply (2): V AC or V AC (±10%) Current dissipation: Weight: 3.5A for 100V system and 1.6A for 200V system 47 pounds (21.3kg) (without options) Sound level: Less than 70dB(A) according to DIN45635, part 19 (EN27779) Page A-2 Printer Specification

179 Appendix B: Magnetic Stripe Encoding This chapter provides information about encoding magnetic stripe data. Inline Encoding on page B 2 Formatting Magnetic Stripe Data on page B 2 ISO Character Code Table on page B 3 7 bit JIS Type II Character Set on page B 4 CR500 Instant Issuance System Installation and User Guide Page B-1

180 Inline Encoding The application can use the magnetic stripe option in the printer to encode data on the card. This function is called inline encoding. The application provides a prefix, usually not visible to the user, to show what type of data to encode. Magnetic stripe encoding data is not printed on a card. Prefix Data Format Character Code Table Maximum Characters ~?0 JIS type 2 7 unit (bit) code 69 ~?1 ISO track 1 (International Air Transport Association IATA) ~?2 ISO track 2 (American Bankers Association ABA) 6 unit (bit) code 76 4 unit (bit) code 37 ~?3 ISO track 3 (Thrift Third Standard TTS) 4 unit (bit) code 104 Formatting Magnetic Stripe Data In most cases, the application chooses the data to encode from the customer record and manages all data checking and formatting. If you are writing a custom application: Data must be formatted with the same continuous font. Only characters specified in the table on page B 3 can be included. Using other characters will result in an error. The maximum number of characters does not include the three prefix characters or the start and end sentinels. Make sure that the ID software or PC application does not process the encoding data as graphics. Magnetic stripe data must be on the first page of the card data. Page B-2 Magnetic Stripe Encoding

181 ISO Character Code Table The following table shows the usable ASCII character codes. The encoding data must use only allowed characters. b b b b4 b3 b2 b P ` p ! 1 A Q a q B R b r # 3 C S c s $ 4 D T d t %* 5 E U e u & 6 F V f v G W g w ( 8 H X h x ) 9 I Y I y A LF * : J Z j z B + ; * K [ k { C, < L \ l D - = M ] m } E. > N ^ n ~ F /? * O _ o DEL* * Do not use shaded characters as encoding data; they are reserved for use by the driver as start or end sentinels. 4 unit code is outlined in a wide green line. 6 unit code is outlined in a narrow magenta line. 7 unit code is outlined in a dashed blue line (except not including DEL) CR500 Instant Issuance System Installation and User Guide Page B-3

182 Start Sentinel (Hexadecimal) End Sentinel (Hexadecimal) 4 unit code (TTS & ABA) ; (3B)? (3F) 6 unit code (IATA) % (25)? (3F) 7 unit code (JIS) DEL (7F) DEL (7F) 7-bit JIS Type II Character Set The maximum number of characters for the JIS format is 69 characters. These characters can include spaces, numeric characters, uppercase alphabetic characters, lowercase alphabetic characters, and the following special characters:! " # $ % & ' ( ) * +,. / : ; < = [ ] ^ _ ~ { } ~ Japanese language characters also are supported from a PC running a Japanese edition of a supported Windows operating system. They include the following: Special characters: 45 Katakana characters: 10 Katakana characters: Page B-4 Magnetic Stripe Encoding