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Datacard® CR500™ Instant Issuance System

Installation and User Guide

August 2013

Part No. 539971-001, Rev. E

NoticePlease 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 AcknowledgmentsDatacard 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.

Proprietary NoticeThe 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. (http://www.openssl.org/). It also includes cryptographic software written by

Eric Young ([email protected]) and software written by Tim Hudson

([email protected]).

Datacard Group11111 Bren Road WestMinnetonka, MN 55343‐9015Phone: 952‐933‐1223Fax: 952‐933‐7971www.datacard.com

© 2012, 2013 DataCard Corporation. All rights reserved.

ii

http://www.datacard.com

http://www.openssl.org/

[email protected]

[email protected]

[email protected]

[email protected]

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/UL60950‐1 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

Regulatory ComplianceNotice for USA (FCC notice)

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.

Notice for CanadaThis 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.

Notice for Europe 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 55022 and to EN 301 489‐5. 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)

警告

此为 A级产品，在生活环境中，该产品可能会造成无线电干扰。在这种情况下，可能需要用户对干扰采取切实可行的措施。

iv

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

Revision LogCR500 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

Table of Contents

Chapter 1: Introduction ____________________________________________________ 1About This Manual _____________________________________________________________ 2Intended Audience ____________________________________________________________ 2Who to Call for Assistance ______________________________________________________ 2

Chapter 2: About the Printer ________________________________________________ 3About the Printer _______________________________________________________________ 4Unpack the CR500 Printer_______________________________________________________ 5The Exterior of the CR500 Printer _________________________________________________ 8Inside the Printer _______________________________________________________________ 9

Inside the Print Unit _________________________________________________________ 9Inside the Security Enclosure _______________________________________________ 10

The Back of the Printer_________________________________________________________ 10Options in the Printer __________________________________________________________ 11

Chapter 3: Installation Requirements_______________________________________ 13Site Guidelines ________________________________________________________________ 14

Operating Environment ____________________________________________________ 14Ventilation Clearance _____________________________________________________ 15

Printer Guidelines _____________________________________________________________ 15Physical Security ______________________________________________________________ 16Network Connection __________________________________________________________ 17Network Security ______________________________________________________________ 17Use Datacard CardWizard _____________________________________________________ 17

Chapter 4: Preparing a Secure Printer ______________________________________ 19Security at Setup ______________________________________________________________ 20Locking and Unlocking the Security Enclosure __________________________________ 20

Unlock the Printer Using the Key ____________________________________________ 20Lock the Printer Using the Key ______________________________________________ 21Unlock the Printer Using Authentication _____________________________________ 22Lock the Printer After Using Authentication to Unlock the Printer ______________ 23

Load Cards ___________________________________________________________________ 24Load Ink Ribbon and Retransfer Film____________________________________________ 26

Load Ink Ribbon ___________________________________________________________ 26Load Retransfer Film _______________________________________________________ 28

Chapter 5: Installing the Printer____________________________________________ 33Use the Bolt-Down Feature_____________________________________________________ 34Install the Concealed Card Stacker ____________________________________________ 35Connect the Power Cords _____________________________________________________ 36Connect the Data Cable ______________________________________________________ 37Power On_____________________________________________________________________ 37

Power On the Printer_______________________________________________________ 38Power Off the Printer_______________________________________________________ 39

vii

Network Setup ________________________________________________________________ 40Retrieve the Printer IP Address ______________________________________________ 40Set a Static IP Address (Optional)___________________________________________ 42Activate the Printer ________________________________________________________ 46Set Up Network Access ____________________________________________________ 49Open Printer Manager_____________________________________________________ 49

Verify Network Communication________________________________________________ 51Print a Test Card ___________________________________________________________ 51Additional Setup Tasks _____________________________________________________ 53CardWizard Setup _________________________________________________________ 53

Chapter 6: Using the Printer________________________________________________ 55Initialize Supplies______________________________________________________________ 56Print Cards____________________________________________________________________ 56

Tips for Printing Cards ______________________________________________________ 56Print Cards From CardWizard_______________________________________________ 57Print Cards Using the Exception Card Slide __________________________________ 57

The Printer Touch Screen_______________________________________________________ 58User Button and Light ______________________________________________________ 58Down Arrow, Up Arrow, and Enter Keys _____________________________________ 59Ribbon Light ______________________________________________________________ 59Card Light ________________________________________________________________ 60Supplies Status Light _______________________________________________________ 60

The Touch Screen LCD Menu System ___________________________________________ 60LCD Menus________________________________________________________________ 61Card Counts ______________________________________________________________ 62Messages and Conditions__________________________________________________ 62

The Print Unit Front Panel _______________________________________________________ 63Connection and Lock Symbols _____________________________________________ 64Keys ______________________________________________________________________ 64Speaker___________________________________________________________________ 65

The Print Unit Front Panel Menu System _________________________________________ 66Use the Print Unit Menus _______________________________________________________ 71

Apply a Second Retransfer Layer ___________________________________________ 71

Chapter 7: Taking Care of Your Printer _____________________________________ 77Remove Rejected Cards_______________________________________________________ 78Cleaning Schedule for Printer __________________________________________________ 79Supplies Required _____________________________________________________________ 80Clean the Printer ______________________________________________________________ 80

Cleaning Kit _______________________________________________________________ 80Clean the Card Cleaning Rollers and Cleaning Unit _________________________ 80Clean the Multicard Hopper _______________________________________________ 83Clean the Print Unit ________________________________________________________ 84Clean the Magnetic Stripe Head ___________________________________________ 88

viii

Clean the Thermal Printhead_______________________________________________ 91Clean the Print Unit Fan Filter _______________________________________________ 92

Prepare the Printer for Transport ________________________________________________ 93Disable Printing ____________________________________________________________ 93Prepare and Package the Printer___________________________________________ 96Package the Printer _______________________________________________________ 97

Chapter 8: Messages and Error Recovery __________________________________ 99Touch Screen Messages _____________________________________________________ 100

Messages on the Printer__________________________________________________ 100Other Messages _________________________________________________________ 100Quick Link to a Message _________________________________________________ 101

Print Unit Roller Layout _______________________________________________________ 123Printer Error Recovery________________________________________________________ 124

Multicard Hopper Jam___________________________________________________ 124Print Unit Hopper Jam____________________________________________________ 125Transfer Jam ____________________________________________________________ 126Turnover Jam____________________________________________________________ 128Retransfer Jam __________________________________________________________ 130Mend a Broken Ink Ribbon or Retransfer Film ______________________________ 132

Chapter 9: Supplies ______________________________________________________ 135Storage Environment for Supplies_____________________________________________ 136Ink Ribbon and Retransfer Film _______________________________________________ 137

Ink Ribbon ______________________________________________________________ 137Retransfer Film___________________________________________________________ 137

Cards ______________________________________________________________________ 138Card Size _______________________________________________________________ 138Card Material ___________________________________________________________ 138

Cleaning Supplies___________________________________________________________ 139Replacement Parts __________________________________________________________ 139

Chapter 10: Using Printer Manager________________________________________ 141Start and Stop Printer Manager_______________________________________________ 142

Start Printer Manager ____________________________________________________ 142Stop Printer Manager ____________________________________________________ 143

Printer Manager Settings_____________________________________________________ 144Status Menu ________________________________________________________________ 145Printer Setting Menu _________________________________________________________ 147

Communication_________________________________________________________ 150ActivityLog ______________________________________________________________ 151ActivityLog Example _____________________________________________________ 152Behavior ________________________________________________________________ 153FrontPanel ______________________________________________________________ 154Print Settings ____________________________________________________________ 155Pick Settings_____________________________________________________________ 160MagStripeGeneral_______________________________________________________ 161

ix

Troubleshooting Menu_______________________________________________________ 162Test Card _______________________________________________________________ 163

Maintenance Menu _________________________________________________________ 165Printer Manager Updates ____________________________________________________ 165

Appendix A: Printer Specification ________________________________________________ A-1General Printer Specifications________________________________________________ A-2Operating Environment Conditions ___________________________________________ A-2Storage Environment Conditions _____________________________________________ A-2

Appendix B: Magnetic Stripe Encoding ___________________________________________ B-1Inline Encoding ______________________________________________________________ B-2Formatting Magnetic Stripe Data ______________________________________________ B-2ISO Character Code Table____________________________________________________ B-37-bit JIS Type II Character Set _________________________________________________ B-4

x

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

About This ManualThis manual provides detailed information about the Datacard® CR500 card printer.

Other manuals included with the system are:

• Quick Install Guide

• Packing List

Intended AudienceThis 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 AssistanceIf 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 +1 800.328.3996 or 952.988.2316

Europe, Middle East and Africa +44 1489555627

Asia Pacific +852 2821 0121

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 1‐800‐568‐4598.

Page 2 Introduction

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


About the PrinterThe Datacard® CR500 card printer uses retransfer printing technology to produce high‐

quality, 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

Unpack the CR500 Printer

Remove the Printer from the Carton

Remove the ties that hold the top and the bottom of the carton together. Do not cut the

ties.

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.

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.

2 1


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.


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.


The Exterior of the CR500 Printer

Print Unit The part of the printer that applies images to cards.

Concealed Output Stacker Printed cards exit the card discharge slot and rest in the Concealed Output

Stacker. Lift the flap to remove the card.

Print Unit Door Open the door to access the ink ribbon and retransfer film cartridges.

Print Unit Door Latch Lift up to open the Print Unit door.

Power Switch Press the switch to power on/off the printer.

Security Enclosure Contains the multicard hopper, touch screen, and the reject card area.

Security Enclosure Door Provides access to load cards, load supplies, and remove rejected cards.

Security Enclosure Lock 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.

O 1


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 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 Printer

Inside the Print UnitCleaning Unit/Card Cleaning Rollers

Removes dust or debris from the cards before printing.

Ink Ribbon Cartridge Holds the ink ribbon.

Ribbon Release Button Press to release and remove the ink ribbon cartridge.

Film Cartridge Holds the retransfer film.

Film Release Button Press to release and remove the retransfer film cartridge.

Concealed Output Stacker Attach the concealed output stacker to the card output slot and card stacker

bracket.

Jog Dials 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.


Inside the Security EnclosureCard Weights Place a card weight on cards loaded in each hopper.

Hopper 1 Holds 70 cards.



Reject Card Area Cards that did not complete successfully are ejected to this secure area.

The Back of the Printer

Security Enclosure Power Plug the power supply cord into the receptacle.

Network Data Port Plug in the network cable.

Fan Filter Open to clean the fan filter and maintain card quality.

Security Lock Port Attach an optional cable lock, such as a Kensington lock, in this location.

Print Unit Power Plug the power cord into the receptacle.

Always use a card weight to ensure accurate picking and transporting of the card, whether or not cards are loaded in the hoppers.


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.


About the Printer

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


Site GuidelinesThe 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

ISO14611‐1. 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 EnvironmentThe 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

Ventilation ClearanceTo 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.


Physical Security The CR500 printer includes the following security features:

Cable 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.

Bolt‐Down 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.

Security Enclosure Lock 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

Network ConnectionThe 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 CardWizardThe 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.


Installation Requirements

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


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 Key1. Insert the key in the lock (A).

2. Press and turn the key clockwise (B).

Page 20 Preparing a Secure Printer

3. Lift the Security Enclosure door to the fully open position.

Lock the Printer Using the Key1. 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).


Unlock the Printer Using Authentication1. Refer to the instructions for your application to unlock the printer using

authentication.

2. At the printer, lift the Security Enclosure door.


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.

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.

B

A

Door sensor and lock pin


Load Cards

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 0.030‐inch (0.75mm) thickness.

• Load up to 70 cards in hopper 1, 50 cards in hopper 2, and 50 cards in 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.

3. Fan or separate cards before placing them in the hopper.

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.

If you plan to use only one hopper, load cards into hopper 3.

Follow your organization’s guidelines to load the correct cards in

hopper 1, hopper 2, and hopper 3.


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 5.

7. After all supplies are loaded, close the Security Enclosure door to lock the printer.


Load Ink Ribbon and Retransfer FilmThe 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.

Load Ink RibbonFollow 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).


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 take‐

up knobs help maintain the proper tension.


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 FilmUse 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.


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).


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.



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.


Preparing a Secure Printer

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


Use the Bolt-Down FeatureTo 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 1.

5. 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

Install the Concealed Card StackerHang 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.


Connect the Power Cords

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.

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.

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.


Connect the Data CableThe 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.

2. Connect the other end of the network cable to a network port (B).

Power OnBefore 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.


Power On the PrinterPress the ““ symbol on the power switch. The printer powers on and begins initializing.

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.

O 1


Power Off the PrinterPress the “O” mark on the printer power switch to power off the printer.

After approximately 10 seconds, the touch screen becomes dark and the printer fan

stops.

O 1


Network SetupThis 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 AddressThe 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 37.

2. 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).


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).


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


2. 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) twice.

6. Press the ENTER key (d).

7. Press the ENTER key (e).


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.


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 2.

13. Press the ENTER key (m) to change the gateway address, following the process in

step 11.


14. Press the ENTER key (n) to restart the printer.

Activate the PrinterTo 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 $ = / +.

To activate the printer and to enable printing:

1. Obtain the activation code:

a. At installation, call Datacard Technical Phone Support at 1‐800‐328‐3996 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.

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.


2. Install the supplies. Refer to “Preparing a Secure Printer” on page 19 for the steps to

follow.


4. 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).


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.


• 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 1‐800‐328‐3996.

8. 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 AccessWork 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 ManagerAfter 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.

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.


1. Get the printer IP address. Refer to “Retrieve the Printer IP Address” on page 40.

2. Open the web browser on the PC.

3. In the Address area of the browser, type the following:

https://printer_IP_address

For example: https://123.12.3.123 where 123.12.3.123 is the printer IP address.

4. Press the ENTER key.

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.

During normal operation, site personnel should not use Printer Manager unless

asked to do so.

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.


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 CommunicationAccessing 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.

Print a Test Card1. 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.


4. At the printer:

a. Pull out the exception card slide and place a plain white card (A) in the slide.

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.

AB


Additional Setup TasksYou 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 SetupYou 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.


Installing the Printer

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


Initialize SuppliesUse 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 CardsPrint 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

Print Cards From CardWizard1. 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.


and ejects the printed card in the Concealed Output Stacker.

Print Cards Using the Exception Card SlideUse 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.

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.


and ejects the printed card in the Concealed Output Stacker.

AB


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 ScreenThe 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 LightThe 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.


• 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:

Down Arrow, Up Arrow, and Enter KeysUse 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.

Ribbon LightThe 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 (not visible) The printer is off.

Green The printer is ready.

Blinking green

The printer is busy.

Amber The printer is not ready.

Blinking Amber

The printer has an error.

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.


Card LightThe 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.

Supplies Status LightThe 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 SystemThe 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.

Off Cards are okay.

Rapid Blinking Green Insert card using exception card slide.

Blinking Amber The printer problem applies to cards.


LCD MenusThe 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.


Card CountsThe 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 ConditionsWhen 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.


The Print Unit Front PanelThe 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 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.

Key Indicator

Speaker

Line 1

Line 2

Connection KeyLocked?


Connection and Lock SymbolsThe Print Unit displays the following symbols that indicate its status.

KeysThe indicators for key functions display as white text on a black rectangle. The Cleaning

display example shows how indicators describe the keys.

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.


The keys can have the following functions:

SpeakerThe speaker provides an electronic beep that indicates that an error has occurred, or

confirms that settings have been saved.

Reset Initializes the printer. Use the Reset key after loading supplies or after an error occurs.

Menu 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.

Enter Displays the next, lower level of the menu.

Next View the next item in the menu.

Arrow Keys Use the Up and Down Arrow keys to display list items within a menu level.

Exit Exits the current menu or menu selection and returns to the previous menu selection.

Return Confirms the user selection. The setting takes effect.

Change Makes it possible to change settings.

Scroll Makes it possible to scroll through values for a setting.

Scroll Right Moves the cursor one position to the right.

Scroll Left Moves the cursor one position to the left.


The Print Unit Front Panel Menu SystemTo 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 RollersMG

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 Test PatternPrinter SettingNetwork 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.

Download 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.


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:YMCKYMCK-POYMCKKYMCK-UV

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.)

Film Type:1000

Datacard retransfer film is available in 1000 frames per roll.

Card Thickness:StandardThin

Only Standard ID-1 cards, 0.030 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 Displays the value set using Printer Manager. Refer to “Print Settings” on page 155.

Black mode Displays the value set using Printer Manager. Refer to “Print Settings” on page 155.

UV Level Not supported.

PO Level Displays the value set using Printer Manager. Refer to “Print Settings” on page 155.



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) 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.

Speed Front (UV) Not supported.

Speed (Back) 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.

Speed (B-UV) Not supported.

MG Peel Mode Displays the value set using Printer Manager. Refer to “Print Settings” on page 155.

Standby:Front WaitBack Wait

Not supported.

Backside Cool:OnOff

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.

Speed 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.

Heat Roller Power Saving:Off or up to 60 minutes

Displays the value set using Printer Manager. Refer to “Behavior” on page 153 for information on specifying the power saver mode.

HR Control:EnableDisable

Displays the value set using Printer Manager.



Setting Display:

Mode:CounterLaminator State

Counter:Total CntHead CntFree CntCleaning CntError Cnt

Contrast

Displays the printer settings.

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.

Buzzer:OnOff

Displays whether the electronic beep sound is On or Off. The sound can indicate an error or can confirm a menu selection.

Unit No.:No. 1 – No. 10

DO NOT USE. The Unit No defaults to 1 for the CR500 printer.



Option MG:NoneISO

Displays the type of magnetic encoder installed.

IC Antenna:NoneInstalled

Displays whether the contactless card option is installed:None: a contactless card option is not installed.Installed: a contactless smart card option is used.

IC Contact:NoneISO Type

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.

Contact IC R/W:NoneInstalled

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.

Bend Remedy HR:NoneInstalled

Displays whether the bend remedy option is installed.

Turn Over:NoneInstalled

Displays whether the turnover (duplex) option is installed.

MG ISO Type:LocoHico

JIS Type:LocoHico

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 102 [A/m] (300[Oe])Hico: 218 x 103 [A/m] (2750[Oe])Refer to “MagStripeGeneral” on page 161 for more information.

Retry Count:0, 1, 2, 3

Displays the value set using Printer Manager. Refer to “MagStripeGeneral” on page 161 for information on setting the retry value.



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 MenusThe Print Unit Front Panel menu system allows you to specify settings that affect how

cards are printed.

Apply a Second Retransfer LayerTo 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.

Network Printer Name DO NOT USE

Host IF:USBLAN

This must be set to USB.

IPv4 DO NOT USE

IPv6 DO NOT USE

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.



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.

4. Press Next 13 times to display the Overcoat menu.

13X


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.


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 10.

10. 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.


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.


Using the Printer

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


Remove Rejected Cards


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.

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.

Page 78 Taking Care of Your Printer

Cleaning Schedule for PrinterClean 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

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.

Yearly 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

Clean the magnetic stripe head as described in “Clean the Magnetic Stripe Head” on page 88.

*Thermal Printhead After every 1000 printed cards

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.


Supplies Required

Clean the PrinterThis section provides information on proper care and cleaning of the CR500 printer.

Cleaning KitEach CR500 printer includes one cleaning kit (Part number 564729‐165) 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 UnitThe 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.

Supply Part Number

Single-Sided Cleaning Cards (10 in pack) 506277-001

Dual-Sided Cleaning Cards (10 in pack) 508458-001

Magnetic Stripe Cleaning Cards (10 in pack) 564729-166

Cleaning Swabs (5 in pack) 507377-001

Isopropanol (90%) —

Lint-free Cleaning Wipes —


3. Clean the rollers.

a. Rinse the blue cleaning rollers with water. Gently rub the rollers under running water.

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.

Caution: Do not use detergents, which can damage the rollers.


e. Move the cleaning card back and forth through the rollers until all debris

possible is removed.

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.

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.


Clean the Multicard HopperThe 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


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.


5. Using the clean end of the card, clean the front track (D), following the instructions in

step 4.

6. Discard the used cleaning card.

7. Close the Security Enclosure door to lock the printer.

or

Continue with the next step in the cleaning process.

Clean the Print UnitThe 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 83.



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.


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.


8. Remove the protective paper from the single‐sided cleaning card (A).

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?.

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.


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.

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.

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.

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.

Use a cleaning card one time only. Using a dirty one can damage the rollers.


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.



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).


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).

6. At the Print Unit:

a. Press Menu to display Cleaning.

b. Press Enter, then press Next to display the MG option.

Optionally, you can insert the magnetic stripe cleaning card in hopper 3.


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

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.

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.


Clean the Thermal Printhead


20 for the steps to follow.

2. Power off the printer.


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.

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.


Caution: The thermal printhead can be damaged by an electrostatic charge. Discharge yourself by touching the Print Unit frame before cleaning the printhead.

Caution: Never use metal or abrasive materials to clean the thermal printhead.


Clean the Print Unit Fan FilterThe 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.

2. Rinse the filter under running water.

3. Allow the filter to dry thoroughly.

4. Replace the fan filter and cover in the printer.

1

2 3


Prepare the Printer for TransportUse 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

• Package the printer

Disable PrintingTo 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).


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).


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 4.

6. Exit the menu system.

Press the USER button repeatedly until Ready displays on Line 1 and the USER button

changes from amber to green.


Prepare and Package the Printer1. Unlock the printer. Refer to “Locking and Unlocking the Security Enclosure” on page

20 for steps to follow.


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 26.

5. 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 28.

6. 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 66.

11. 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.


Package the Printer1. Place the printer in the plastic bag.

2. Package the printer in the original shipping carton.

3. Secure the shipping straps.

4. Provide the activation code to the recipient of the printer.

OR


Taking Care of Your Printer

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


Touch Screen MessagesThe 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• 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.

Other Messages• 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

Quick Link to a MessageNumber 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


“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 101: Job could not complete

Message Source / Text Possible Cause Solution

Security Enclosure A message was cleared while the printer was open.

Close the Security Enclosure door to lock the printer before resuming operation. Refer to “Locking and Unlocking the Security Enclosure” on page 20.

Security Enclosure The setting change requested is not supported.

Use the Printer Manager to change settings, and choose a value within the range shown.

Print Unit:Security Key 21, 22, or 23

A security key (number) was set in the Print Unit.

DO NOT set a security key in the Print Unit. If a security key was set, contact your service provider for assistance.


Security Enclosure The card took too long to complete.

The card is canceled. Check your card design and send the card again.


Message 103: Printer problem

Message 104: Critical problem


Print Unit:No Card D0

Print Unit problem with handling cards.

Power the printer off and then on. If that does not solve the problem, contact your service provider for assistance.

Print Unit: Codes A1, 20, 24, 26, 27, FB,

The printer has a control problem.


Security Enclosure The printer has a control problem.


Security Enclosure The card did not reach the Print Unit input area.


Security Enclosure The message needs to be cleared from the touch screen.

Press the User button to display Ready on the touch screen.


Print Unit:Hardware 44

Print Unit operation problem.

Contact your service provider for assistance.

Print Unit:Hardware D8

Print Unit operation problem.


Print Unit:Cam Error C1

Cam operation problem.


Print Unit:HR Overheat C2

Heat roller operation problem.


Print Unit:Head Overheat F8

The thermal head is overheated.



Print Unit:TR Overheat F0

The retransfer roller is overheated.


Print Unit:TR heater F1

Retransfer roller operation problem.


Print Unit:TR Thermister F2

Retransfer roller operation problem.


Print Unit:RR Overheat F3

Bend Remedy roller operation problem.


Print Unit:RR Heater F4



Print Unit:RR Thermister F5



Print Unit:Power Intrpt C3

Power was interrupted for a short time.


Print Unit:Head Overheat F8

The thermal head is overheated.


Print Unit:EEProm Broken FA

EEPROM malfunction Contact your service provider for assistance.

Print Unit:MG Mechanical AB

Magnetic stripe mechanical problem


Print Unit:MG Hardware AC

Magnetic stripe hardware problem


Security Enclosure The printer has an internal problem.



Message 105: Magstripe data error

Message 106: Magstripe data not found


Security Enclosure The printer failed to verify the correct magnetic stripe data was written to 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.

Print Unit:MG Test ErrORMG Write Error in Self Test A8

A writing error has occurred during magnetic encoder self-diagnosis.


Print Unit:MG Read Error AE

A problem occurred during magnetic encoding data reading.

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.

Print Unit:MG Write Error AD

A problem occurred during magnetic encoding data writing.

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.


Security Enclosure The printer did not fine magnetic stripe data on the card.



Message 108: Magstripe read no data

Message 111: Card not picked

Message 112: Card hopper empty


Security Enclosure The printer did not find magnetic stripe data on the card.


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.


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.


Message 113: Close cover to continue

Message 114: Cover opened during job

Message 115: Wait for print temperature


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.


Security Enclosure The printer was opened during a job.



Security Enclosure


Message 116: Magstripe not available

Message 118: Print ribbon type problem

Message 119: Print ribbon not supported


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.


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.


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.


Message 120: User paused the printer

Message 121: Print ribbon ID problem

Message 122: Magnetic stripe format problem


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.


Security Enclosure The printer cannot identify the installed ribbon.

Use ribbon support by the printer. The card is canceled.


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.


Message 123: Insert new card side 1 up

Message 124: Insert same card side 1 up

Message 149: Option not installed


Security Enclosure A new card must be inserted in the printer.

Insert a new card in the printer with side 1 facing up.


Security Enclosure The same card must be inserted in the printer.

Insert the same card with side 1 facing up.


Print Unit:IC Encoder not installed 2CORMG Encoder not installed 2DOROption 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.


Message 150: Print while unlocked

Message 151: Failed to lock

Message 152: Insert new card side 2 up


Security Enclosure The printer is unlocked and a card was sent.



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.


Security Enclosure A new card must be inserted in the printer.

Insert a new card with side 2 facing up.


Message 153: Insert same card side 2 up

Message 154: Print unit not available

Message 155: Room temperature too low


Security Enclosure The same card must be inserted in the printer.

Insert the same card in the printer with side 2 facing up.


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.


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.


Message 156: Printer warming up

Message 157: Input hopper card jam

Message 158: Check print unit front panel


Print Unit:Preheating DA

Preheating is in progress.

Wait until preheating is complete. This message clears without pressing the User button.


Security Enclosure One or more cards were in the card track when the printer was powered on.

Press the User button to clear the message. The printer attempts to place the card back in the hopper.

Security Enclosure 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.

Remove the card. Refer to “Multicard Hopper Jam” on page 124 for the steps to follow.Press the User button to clear the message.


Print Unit:Please, Power Off

The power must be turned off to initialize the printer.

Turn the power switch off and then on again.


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.

The Print Unit has been set to Transport Mode.

Complete any work using the front panel. Close the Print Unit door and then close the Security Enclosure door to lock the printer.

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.


Message 159: Print unit card jam


Print Unit:Jam (Hopper) 90

There is a card jam in the hopper section.

Remove the jammed card from the card hopper. Refer to “Multicard Hopper Jam” on page 124 and “Print Unit Hopper Jam” on page 125.

Print Unit:Jam (Turnover) 91

There is a card jam in the turnover section.

Remove the jammed card from the turnover section. Refer to “Turnover Jam” on page 128.

Print Unit:Jam (MG) 92

There is a card jam in the magnetic stripe encode section.

Remove the jammed card from the turnover section. Refer to “Turnover Jam” on page 128.

Print Unit:Jam (Transfer) 93

There is a card jam in the card feed rollers.

Remove the jammed card. Refer to “Transfer Jam” on page 126.

Print Unit:Jam (Discharge)94

There is a card jam in the card discharge section.

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.

Print Unit:Jam (Retransfer) 95

There is a card jam near the retransfer rollers.

Remove the jammed card from the retransfer section. Refer to “Retransfer Jam” on page 130.


Message 160: Set print unit to download

Message 161: Retransfer film problem

Message 162: Retransfer film out


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.


Print Unit:Media Search A1ORFilm 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.


Print Unit:Film Run Out A2ORMedia 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.


Message 163: Clear hopper card track

Message 164: Ink ribbon problem

Message 165: Ink ribbon out


Security Enclosure A card is in the exception card slot.

Slide out the exception card slide and remove the card. Press the User button to clear the message.

Security Enclosure One or more cards were in the card track when a message was cleared with the User button.

Remove the card. Refer to “Multicard Hopper Jam” on page 124 for the steps to follow.Press the User button to clear the message.


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.


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.


Message 169: Move retransfer film one panel

Message 173: Improper shutdown

Message 181: Input Hopper Problem


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.


Security Enclosure The printer was not shut down correctly, or facility power was interrupted.

Press the User button to clear the message.


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.


Message 182: Input Hopper Jam two cards

Message 183: Input Hopper jam card lost

Message 184: Input Hopper jam card at exit


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.


Security Enclosure The card did not arrive at the hopper exit. Either the card was not picked, or it was dropped.

This could indicate a problem with the rotary or linear offsets.

Remove the card if it was picked. Refer to “Multicard Hopper Jam” on page 124 for the steps to follow.


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.


Message 185: Input Hopper jam print input

Message 186: Input Hopper Jam at exit

Message 187: Input Hopper Jam print input


Security Enclosure A card is already at the entrance of the Print Unit.



Security Enclosure A card remained at the multicard hopper exit and did not reach the Print Unit.


Security Enclosure 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.



Security Enclosure The card still did not reach the Print Unit after an attempt to move it into the Print Unit.



Message 188: Input Hopper Jam print input

Message 189: Input Hopper jam card at exit

Message 190: Input Hopper jam exception


Security Enclosure A card is already at the entrance of the Print Unit when another card is to be picked.



Security Enclosure A card is at the hopper exit during hopper reset.



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 191: Input Hopper jam print input

Message 192: Input Hopper Jam exception

Message 193: MultiHopper Jam two cards


Security Enclosure A card is at the entrance of the Print Unit during a hopper reset.



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.


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.


Message 194: MultiHopper jam card lost

Print Unit Roller LayoutUnlock 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.


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.


Printer Error RecoveryThe 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 JamIf 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.


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.



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 JamIf a card jams in the input area or cleaning roller area of the Print Unit:



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.


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).

5. Replace the cartridge.

6. Close the Print Unit door. Press Reset and then Enter on the Print Unit front panel.




Transfer JamIf 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.

If a card jams in the input areas of the Print Unit:





b. Locate the jammed card.

Caution: Some internal parts may be hot. Wear a glove when reaching into the printer or let it cool first.


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.










Turnover JamIf 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.





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.

Caution: Some internal parts may be hot. Wear a glove when reaching into the printer or let it cool first.


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 5.

4. 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.





7. Replace the cartridges.





Retransfer JamIf a card jams in the retransfer section, the Jam (Retransfer) message displays. Use the

following procedure to remove the jammed card.





b. Press the retransfer film cartridge eject button and remove the retransfer film

cartridge.

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.

Caution: The card might be stuck to the film. Watch carefully to avoid jamming the card when removing the retransfer film cartridge.


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).



7. Power on the printer.


8. Press Reset. The Card Jam Removed? message displays on the Print Unit front panel.

Press Yes if the card has been removed.




Mend a Broken Ink Ribbon or Retransfer FilmIf 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.



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.

7. Align the ends of the broken media and apply tape to secure them.

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.

Do not remove the used ink ribbon or film from the take‐up spool.


8. Turn the take‐up spool counterclockwise until the mended portion is wound onto the

spool two or three turns.

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.





Take-upSpool

Tape


Messages and Error Recovery

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


Storage Environment for SuppliesFollow 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

Ink Ribbon and Retransfer FilmInk 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:

Retransfer FilmThe following retransfer film is available:

568971‐103 (Prints up to 1000 single‐sided cards.)

Type Part NumberMaximum Cards/Roll Purpose

YMCK-I (or YMCK-PO)

506276-003 750 Full color with a non-printing (peel-off) area on one or both sides.


CardsThis 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.

Use cards that conform to the following specifications:

• ISO/IEC 7810 Type ID‐1

• ISO/IEC 7811‐2 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.

Card SizeUse ISO‐1 (CR‐80) size cards with the following nominal dimensions:

Card MaterialFor best results, use cards made from one of the following materials:

• PVC

• PET

• PET‐G

• Polycarbonates

• ABS

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.

Length 3.375 inches 85.6 mm

Width 2.125 inches 54 mm

Thickness 0.030 inch 0.75 mm

Page 138 Supplies

Cleaning SuppliesThe printer needs the following cleaning supplies. For best results, keep cleaning supplies

on hand.

Replacement PartsThe following replacement parts are available:

Type Part Number

Cleaning cards 506277-001, pack of 10 cards

Dual-sided cleaning cards 508458-001, pack of 10 cards

Printhead cleaning swabs 507377-001, pack of 5 swabs

Magnetic head cleaning cards 564729-166, pack of 10 cards

Cleaning roller unit 534717-101

Printer fan filter 534717-134

White glove 534717-339

Power Supply 810499-001

Card Weight 504416-001

Power Cords Contact your local service provider for the correct power cord for your location.


Supplies

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


Start and Stop Printer ManagerThe 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 Manager1. Get the printer IP address. Refer to “Retrieve the Printer IP Address” on page 40.

2. Open a web browser on the PC.

3. In the Address area of the browser, type the following:

https://printer_IP_address

For example: https://123.12.3.123 where 123.12.3.123 represents the printer IP

address.

4. Press the Enter key.

5. In the Printer Manager Please Log In area, select a Username and enter a password, if

one is required.

During normal operation, site personnel should not use Printer Manager unless

asked to do so.

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.

Page 142 Using Printer Manager

• 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:

• 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.

Stop Printer ManagerSelect Log Out from the menu to end the current Printer Manager session. For security,

close the browser window after logging out.


Printer Manager SettingsThe 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.


Status MenuThe 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 1. Manufacturer2. Model3. Agency Model4. Options Installed5. Serializations6. Versions

Displays vital product data (VPD) information, including the manufacturer, model, options, and version information.

Printer Status 1. Printer State2. Seconds On3. Current Conditions4. Job Status

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.


Supplies 1. Ribbon Part Number2. Ribbon Lot Code3. Ribbon Remaining4. Ribbon Max Length5. Ribbon Serial Number6. Ribbon Module7. Ribbon Supported8. Ribbon Action Sequence9. Ribbon Supply Code10. Ribbon Special Code11. Ribbon Region Code12. Ribbon Product Code

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.

Audit Data 1. CardsPickedInputHopper12. CardsPickedInputHopper23. CardsPickedInputHopper34. CardsPickedInputHopper

Exception5. GoodCards6. LostCards7. PrinterStartupCount8. PrintJobCancels9. PrintJobRecoveryAttempts10. PrintJobRestarts11. PrintJobResumes12. PrintJobsFailed13. PrintJobsReceived14. PrintJobsRun15. PrintJobsSucceeded16 – 30. Resettable

counters31. SameCardSecond

SidePicks

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.



Printer Setting MenuThe Printer Setting menu allows you to view and change printer settings.


Communication (A)

1. EthAddressMethod2. EthDnsAddress13. EthDnsAddress24. EthDnsSearchSuffix5. EthGatewayAddress6. EthIpAddress7. EthSubnetMask

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.

ActivityLog (A) 1. ExternalLog2. ExternalLogServer3. FilterCardActions4. FilterConfigChanges5. FilterJobStates6. FilterSoapMsgs7. FilterSystem8. InternalLog

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.


Behavior (A) 1. ActivityLogExternal2. ActivityLogInternal3. DPCL4. DPCL25. DPCL2Secure6. DPCLSecure7. Remake8. RemakeMethod9. RetrieveDataTimeout10. PowerSaverMode11. 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) 1. LcdConfigMenu2. LedRibbonLow

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.

Print (A) 1. SettingsGroupPurpose2. ApplyBendRemedy3. BacksideCooling4. BendRemedyRetransfer

RollerTemp5. KPower6. OffsetCardX7. OffsetPrtX8. OffsetPrtY9. OffsetTrfX10. PeelOffPower11. ResinBlackMode12. RetranferRollerTemp13. YMCPower

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.



Pick (A) 1. ExceptionLinearOffset2. ExceptionRotationOffset3. Hopper1LinearOffset4. Hopper1RotationOffset5. Hopper2LinearOffset6. Hopper2RotationOffset7. Hopper3LinearOffset8. Hopper3RotationOffset

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.

MagStripeGeneral (A)

1. Coercivity2. ISOHICOMode3. Track1Format4. Track2Format5. Track3Format6. RetryCount

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.



CommunicationUse the Printer Setting menu Communication options to specify the Ethernet address

method used by the printer.

Option Description

EthAddressMethod Specify the communication method used by the printer. Options are DHCP and STATIC.

EthDnsAddress1

DNS server information.EthDnsAddress2

EthDnsSearchSuffix

EthGatewayAddress If EthAddressMethod is STATIC, enter the gateway address for the network. If EthAddressMethod is DHCP, the DNS server controls this setting.

EthIpAddress If EthAddressMethod is STATIC, enter the IP address for the network. If EthAddressMethod is DHCP, the DNS server controls this setting.

EthSubnetMask If EthAddressMethod is STATIC, enter the subnet mask for the network. If EthAddressMethod is DHCP, the DNS server controls this setting.


ActivityLogUse 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 Description

ExternalLog Enable or disable writing the Activity Log to an external Syslog server.

ExternalLogServer Specify the IP Address of the external syslog server, if ExternalLog is set to Enabled.

FilterCardActions Write the start and completion of a card action with the specified severity, and higher, to the activity log.

Default: Notice

FilterConfigChanges Write configuration change actions with the specified severity, and higher, to the activity log.

Default: Notice

FilterJobStates Write changes to the state of a print or exception job with the specified severity, and higher, to the activity log.

Default: Notice

FilterSoapMsgs Write DPCL/Soap (Simple Object Access Protocol) messages from the printer with the specified severity, and higher, to the activity log.

Default: Notice

FilterSystem 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

InternalLog Enable or disable the Activity Log on the printer.

Default: Enabled


ActivityLog ExampleThe 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.


BehaviorUse the Printer Setting menu Behavior options to control the printer operation.

Option Description

ActivityLogExternal Enable or disable writing the activity log to an external syslog server.

Default: Enabled

ActivityLogInternal Enable or disable the internal activity log.

Default: Enabled

DPCL Enable or disable DPCL command access to the printer through the unsecured port.

Default: Enabled

DPCL2 Enable or disable DPCL2 command access to the printer through the unsecured port.

Default: Enabled

DPCL2Secure Enable or disable DPCL2 command access to the printer through the secure port.

Default: Enabled

DPCLSecure Enable or disable DPCL command access to the printer through the secure port.

Default: Enabled

Remake 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

RemakeMethod 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

RetrieveDataTimeout 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.


FrontPanelUse the Printer Setting menu FrontPanel options to customize the printer LCD touch

screen.

PowerSaverMode 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, 60Default: 30 minutes

WebServerSecure 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.

Option Description

LcdConfigMenu Enable or disable the Configuration menu display on the LCD touch screen.

Default: Enabled

The Status and Maintenance menus cannot be disabled.

LedRibbonLow Set the percentage of ribbon remaining before being notified that the ribbon is low and should be changed.

Range: 0 to 1000000Default: 10 percent

Option Description


Print SettingsUse the Printer Setting menu Print options to control the quality of the printing.

Option Description

SettingsGroupPurpose Describes the purpose of a settings group. Use it to state the reason for creating a settings group.

ApplyBendRemedy 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.

BacksideCooling 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.

BendRemedyRetransferRollerTemp

Increase or decrease the temperature of the bend remedy roller.

Range: –5 to 0 special unitsDefault: 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.


KPower 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 unitsDefault: 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

Option Description


OffsetPrtX Sets the position of printing on the card in the short direction.



If the image is not centered on the card in the short direction, contact your service provider for assistance to change this setting.

OffsetPrtY Sets the position of printing on the card in the long direction.



If the image is not centered on the card in the long direction, contact your service provider for assistance to change this setting.

Option Description

�

A=2.15mm

B=2.07mm

Y

BACK

FRONT

XLEFT RIGHT

Printing startCard shifting direction

R

G

B


OffsetTrfX Sets the position of retransfer printing on the card in the long direction.



If the image is not centered on the card in the long direction, contact your service provider for assistance to change this setting.

PeelOffPower 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 unitsDefault: 0

Decrease the PeelOffPower value to reduce wrinkling on the Peel-off panel or to prevent ribbon breaks when you use a Peel-off ribbon.

ResinBlackMode 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.

Option Description

�

A=2.15mm

B=2.07mm

Y

BACK

FRONT

XLEFT RIGHT

Printing startCard shifting direction

R

G

B


RetransferRollerTemp Increases or decreases the temperature of the retransfer roller.


• 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.

YMCPower 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.


• Increase the YMCPower to make color printing more intense. • Decrease the YMCPower to reduce intensity or to prevent

ribbon breaks while printing colors.

Option Description


Pick SettingsThe 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 Description

ExceptionLinearOffset Sets the linear offset to pick a card from the Exception Card Slide.

Range: –500 to 500 stepsDefault: 0

ExceptionRotationOffset Sets the rotational movement offset to pick a card from the Exception Card Slide.


Hopper1LinearOffset Sets the linear offset to pick a card from hopper 1.


Hopper1RotationOffset Sets the rotational movement offset to pick a card from hopper 1.











MagStripeGeneralMagnetic stripe settings are available for WebAdmin and WebService access‐level users

to set up basic magnetic stripe options.

Option Description

Coercivity 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, LOCODefault: HICO

ISOHICOMode Select the HICO mode for the magnetic stripe.

Range: Standard, SuperDefault: Standard

Track1Format Specify the data format for track 1.

Range: None not used6unit alphanumeric, 76 characters7unit alphanumeric, 69 charactersAAMVA6unit AAMVA, 79 charactersJIS2 JIS2, 7 unit code, 69 characters

Default: 6unit


Range: None not used4unit numeric, 37 characters

Default: 4unit


Troubleshooting MenuThe options on the Troubleshooting menu allow you to print test cards, manage the audit

log, and reset card counts.


Range: None not used4unit numeric 104 characters7unit alphanumeric, 69 charactersAAMVA6unit 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 3Default: 2

Option Description


Test CardUse 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.


Test Card (A) 1. Input Hopper Number2. Magnetic Stripe3. Color4. Monochrome5. Test Pattern to use for

Color and/or Monochrome

6. Copies7. Park Smart Card8. Park Position9. Smart Card Park Time10. 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) 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 Log (A) Reset the log. Click Run in the Reset Log submenu to remove all of the entries from the Activity Log.

Reset Counters (A)

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.

Printer Reset (A) 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.

Option Description

Input Hopper Number Select the input hopper number where the test card to be used is loaded.

Magnetic Stripe Print the card with encoded magnetic stripe data.


Color Print the test card using the YMCK panels of the print ribbon on the front or back.

Monochrome Print the test card using a monochrome ribbon (or the K panel of a color ribbon) on the front or back.

Test Pattern to use for Color and/or Monochrome

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 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.

Park Position Select the smart card park position from the following: ContactSmartCard or ContactlessSmartCard.

Smart Card Park Time Enter the amount of time to hold the test card in the smart card bay, from 0 to 300 seconds.

Default: 10 seconds

Do not eject card Select this option to prevent the test card from being ejected from the printer.

Option Description


Maintenance MenuUse 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.

Printer Manager UpdatesPrinter 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.

Menu Item Description

Updates (A) 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.


Using Printer Manager

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

General Printer Specifications

Operating Environment Conditions

Storage Environment Conditions

Recording method: Dye Sublimation Retransfer

Feed format: Automatic feed

Recording density: 300 dpi

Reproduction gradations:

256 levels each Yellow (Y), Magenta (M), and Cyan (C); 2 for Black (K)

Printing time: 29 seconds (single-sided, excluding data transfer time)

Interface: Ethernet (100Base-Tx or 10Base-T)

Temperature: 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)

Humidity: 35% to 70% (non-condensing)35% to 60% if using Peel-off ribbon

Temperature: 5°F to 131°F (-15°C to 55°C)

Humidity: 20 to 80%

Power supply (2): 100-120V AC or 220-240V AC (±10%)

Current dissipation: 3.5A for 100V system and 1.6A for 200V system

Weight: 47 pounds (21.3kg) (without options)

Sound level: Less than 70dB(A) according to DIN45635, part 19 (EN27779)

Page A-2 Printer Specification

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

Inline EncodingThe 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.

Formatting Magnetic Stripe DataIn 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.

Prefix Data FormatCharacter Code Table

Maximum Characters

~?0 JIS type 2 7 unit (bit) code 69

~?1 ISO track 1 (International Air Transport Association — IATA)

6 unit (bit) code 76

~?2 ISO track 2 (American Bankers Association — ABA)

4 unit (bit) code 37

~?3 ISO track 3 (Thrift Third Standard — TTS) 4 unit (bit) code 104

Page B-2 Magnetic Stripe Encoding

ISO Character Code TableThe following table shows the usable ASCII character codes. The encoding data must use

only allowed characters.

* 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)

b7 0 0 0 0 1 1 1 1

b6 0 0 1 1 0 0 1 1

b5 0 1 0 1 0 1 0 1

b4 b3 b2 b1 0 1 2 3 4 5 6 7

0 0 0 0 0 0 @ P ` p

0 0 0 1 1 ! 1 A Q a q

0 0 1 0 2 “ 2 B R b r

0 0 1 1 3 # 3 C S c s

0 1 0 0 4 $ 4 D T d t

0 1 0 1 5 %* 5 E U e u

0 1 1 0 6 & 6 F V f v

0 1 1 1 7 ‘ 7 G W g w

1 0 0 0 8 ( 8 H X h x

1 0 0 1 9 ) 9 I Y I y

1 0 1 0 A LF * : J Z j z

1 0 1 1 B + ; * K [ k {

1 1 0 0 C , < L \ l |

1 1 0 1 D - = M ] m }

1 1 1 0 E . > N ^ n ~

1 1 1 1 F / ? * O _ o DEL*

CR500 Instant Issuance System Installation and User Guide Page B-3

7-bit JIS Type II Character SetThe 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:

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)

Page B-4 Magnetic Stripe Encoding

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