RP90 Card Printer and RL90 Card Laminator: User guide June 2005 Part Number 564774-001
Please note and heed the WARNING and CAUTION labels that have been placed on the equipment for your safety. Please do not attempt to operate or repair this equipment without adequate training. See “Safety” on page vii for the basic safety tips to ensure safe operation and maintenance of this equipment Regulatory compliance These Datacard Group products conform to regulatory requirements as specified in North America, Europe, and Asia. See “Regulatory compliance” on page 66 for more information.
Contents Liability statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Safe environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Safe human interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 About this manual . .
Viewing and changing printer settings . . . . . . . . . . . . . . . . . . . . 21 Printing Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Setup tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Print/Encode tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Color tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Printing Properties . . . . . . . . . . . . . . . . . . . .
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Ink ribbon, retransfer film, and laminator material. . . . . . . . . . 56 Ink ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Retransfer film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Laminator material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liability statement Liability statement This Datacard® product has been built to the high standards of DataCard Corporation (doing business as Datacard Group). Please note and heed the WARNING and CAUTION labels that 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.
Introduction 1 About this manual This manual provides detailed information about the Datacard® RP90 card printer and the optional Datacard® RL90 card laminator. The first section provides operators with basic information about the printer and laminator including drawings and parts identification. The second section provides the information needed to use the printer, and the third section talks about viewing and changing printer settings including printing preferences and setting properties.
About the Printer About the Printer The Datacard RP90 card printer uses retransfer printing technology to produce highquality, edge-to-edge printing on one or both sides of a variety of PVC and non-PVC card surfaces, including contact and contactless smart cards. The retransfer printing process uses two ribbon types –a color ink ribbon and a retransfer film. The ink ribbon is available in YMCK (Yellow, Magenta, Cyan, and Black) or YMCKK format.
About the Printer The inside of the printer Retransfer film cartridge Holds the retransfer film. Film cartridge eject button Press to release and remove the film cartridge. Ink ribbon cartridge Holds the ink ribbon. Ink ribbon cartridge eject button Press to release and remove the ink ribbon cartridge. Card discharge slot Cards removed from the print area exit here. If the optional RL90 laminator is installed, cards exit the printer and enter the laminator here.
About the Printer The back of the printer 4 Power receptacle Plug in the power cord. USB port Plug in the USB cable. Laminator connection port Used to connect the optional laminator module or other optional equipment. Future expansion ports Not used at this time.
About the Printer About the Laminator The Datacard® RL90 card laminator is an optional laminating module that works with the RP90 printer to add topcoat or patch material to printed cards. Holographic laminating material is also available for added security and tamper resistance. A printed card can be laminated manually by simply inserting it into the laminator, or automatically by transferring the printed card from the RP90 printer to the laminator module.
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Using the printer 2 This section describes how to perform basic tasks required to operate the Datacard® RP90 printer and the Datacard® RL90 card laminator.
Load Supplies Load Supplies Load cards Tips: Handling cards • Do not open the card hopper when “Loading” is displayed on the LCD panel. • Do not touch the surface of cards before printing them. (Oils on hands will reduce printing quality.) • Handle cards by the edges or wear cotton gloves. • Cards can stick together. Slide or fan cards to separate the edges. • Orient all cards the same way. • Do not use cards that are bent or otherwise damaged.
Load Supplies Load ink ribbon Tips: Handling ink ribbon • Do not touch the printing surface of the ink ribbon. (Oils on hands will reduce printing quality.) 1 Slide the door latch to the right and open the printer door. 2 Press the ink ribbon cartridge eject button to remove the orange cartridge. • Place the cartridge on a smooth level surface when loading or reloading. 3 Remove both used ribbon spools from the cartridge (if present).
Load Supplies Load retransfer film Tips: Handling retransfer film 1 • Place the cartridge on a smooth level surface when loading or reloading. Slide the door latch to the right and open the printer door. 2 • Do not touch the printing surface of the retransfer film. (Oils on hands will reduce printing quality.) Press the retransfer film cartridge eject button to remove the green cartridge. 3 Remove both used film spools from the cartridge (if present).
Load Supplies Load laminate Tips: Handling patch or topcoat material • After powering on the laminator, the patch or topcoat material must be initialized. Press the laminator’s RESET/ and then the ENTER keys to initialize the material. 1 Open the laminator door by pulling the top of the door toward you. 2 Press the laminator cartridge eject button and remove the laminator cartridge carefully. The material must be tight when removing the cartridge.
Power on Power on Check the PC connection The printer and PC are connected when the printer is set up. To avoid receiving error messages on the LCD panel, make sure that all supplies are properly loaded and in position before powering on the printer. Before you begin processing cards, check the following: 12 • The printer door and card hopper are closed securely. • The USB data cable (with ferrite bead) is securely connected to the printer and the PC.
Power on Optional laminator connection When using the optional RL90 laminator, check the following: RP90 and RL90 User Guide • The optional laminator cable is securely connected to the printer and the laminator. • The power cord is connected to the laminator and appropriate grounded power source. • Supplies are loaded and the laminator door is closed securely.
Power on Power on the laminator Tips for laminator power • When connected to a printer, laminator messages will not be displayed until the printer is powered on. • Wait while the laminator initializes. • Follow the guidelines for your organization about when to power the laminator on and off. • Check that the red INLET switch, located on the back of the laminator, is set for your input voltage.
Power on Power on the printer Tips for printer power • To avoid recieving errors on the LCD panel, make sure that all supplies are properly loaded and in position before powering on the printer. • Wait while the printer initializes. • Follow the guidelines for your organization about when to power the printer on and off. 1 Press the “|" symbol on the power switch. 2 The printer powers on. The LCD panel shows the firmware version and the printer begins initializing.
Prepare to print cards Prepare to print cards Set the ink ribbon type Tips – Ink ribbon • Reset the ink ribbon type when you set up the first time and if you change the type of ink ribbon. 1 Press the MENU key until "Ink" is displayed. 2 Press the ENTER key. 3 Use the up and down arrow keys to select the type of ink ribbon you are using –YMCK or YMCKK. (YMCK+PO is not available at this time.) 4 Press the ENTER key after selecting the ink ribbon type.
Prepare to print cards Set the retransfer film type Tips – Retransfer film • Reset the retransfer film type each time you change the type of retransfer film you are using. 1 Press the MENU key until "Retransfer" is displayed. 2 Press the ENTER key. 3 "Media Type" is displayed. 4 Use the up and down arrow keys to select Std (1000/roll). Selections of 250 and 750 are not available at this time. 5 Press the ENTER key. 6 Press EXIT twice to return to the "Ready" display.
Printing cards Printing cards Cards can be sent from ID software such as Datacard® ID Works® identification software. ID software handles the types of information used on cards. If you do not have ID software, you can use another PC application to format the information to print on cards; however, most PC applications do not support magnetic stripe encoding or smart card programming. With any application, test the card design to verify the results.
Print from a PC application Tips – Printing • • • During the printing operation, do not open the printer or optional laminator’s door. Do not open the card hopper when the printer’s LCD panel displays “Loading” through “Retransfer”. Do not turn the power off during the printing or laminating process. • Do not unplug the printer or optional laminator during printing or laminating. Use the application's page setup feature to set the following: — Set paper or page size to CR80 card or 2.125" x 3.
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Viewing and changing printer settings This section describes how to view and change printer and laminator settings.
Printing Preferences Printing Preferences The Printing Preferences dialog box contains the Setup, Print/Encode, and Color tabs. 1 Choose Start from the Windows task bar. 2 Choose Settings and then Printers (and Faxes). The Printers (and Faxes) window opens. 3 Click once on the Datacard RP90 printer icon to select it. — The driver must be installed for the printer icon to be present. — Datacard RP90 U1 is the default name of the printer. The name of your printer might be different.
Printing Properties Printing Properties The Printing Properties dialog box options are set up when the printer is installed or by your system administrator. 1 Choose Start from the Windows task bar. 2 Choose Settings and then Printers (and Faxes). The Printers (and Faxes) window opens. 3 Click once on the Datacard RP90 U1 printer icon to select it. — The driver must be installed for the printer icon to be present. — Datacard RP90 U1 is the default name of the printer.
Using the LCD menus Using the LCD menus Printer The printer's LCD panel has a 2-line display, six keys, a Ready light, Error light, and speaker. The display background color changes according to the printer's function; the background is bright green during initialization, orange while processing a card, and red on printer error. These colors can be changed using the LCD panel. Ready LED (green) Steady Green The printer is ready and waiting to print cards. Blinking The printer is receiving data.
Using the LCD menus LCD Display Line one of the display shows the current printer or mode status. The > symbol following a menu selection indicates that there are subcategories listed within the selection. Use the up and down arrow keys to select these options. Press the MENU key and "User Mode" is displayed on the LCD panel. The LCD panel changes to read "Display" within 0.5 seconds.
Using the LCD menus Printer LCD panel Menu Display Settings Function Display Counter Use the up and down arrow keys to select the card counter type: • Total, the printer’s default setting, 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 print head is replaced. • The Free counter displays the number of cards that have printed.
Using the LCD menus Menu Display Settings Function Buzzer ON or OFF Use to turn the electronic beep sound ON or OFF. The sound can indicate an error, when fewer than 20 cards remain in the card hopper, or to confirm a menu selection. Power Saving OFF or up to 60 minutes The printer enters power save mode after a specified period of inactivity. Choose from OFF or select from 5 to 60 minutes in 5 minute increments. “Sleeping” appears on the LCD display.
Using the LCD menus Laminator When you power on the laminator, it begins initializing. The laminator searches for laminate and then starts preheating. The laminator is ready when the LCD display reads "Ready" and the Ready light is steady green. Ready LED (green) Steady Green The laminator is ready. Blinking The laminator busy. Off The laminator stopped because of an error, initialization or preheating is in progress, or the operator is using the LCD panel to set preferences.
Using the LCD menus Laminator LCD panel LCD Display Settings Function Mode Single Pass Default setting; laminates on one side only. Passes card without laminating. Film 1-mil 0.6 mil overlay Default setting for patch film 1-mil thick. For patch film 0.6-mil thick. Use with topcoat with no positioning markings. Film Position -7 to +7 Adjusts the patch transfer position. Default setting is 0; the patch moves to the right with a positive value and to the left with a negative value.
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Taking care of your printer This chapter provides information to help you maintain the Datacard® RP90 printer and the Datacard® RL90 card laminator for optimal performance.
Cleaning the printer Cleaning the printer This section provides information on proper care and cleaning of the RP90 printer and includes cleaning and replacement frequency recommendations. Card cleaning rollers Tips – Card cleaning roller • Wash the card cleaning rollers regularly, such as every time you change the ink ribbon. The card cleaning rollers are located inside the card hopper and clean lint and other debris from the cards before printing.
Cleaning the printer Heat roller Tips – Cleaning card feed and heat rollers • The heat roller cannot be cleaned while hot. Power the printer off and allow to cool or perform cleaning before the heat roller reaches operating temperature. • Clean the card feed rollers and heat roller every 1,000 printed cards. • Use the cleaning card one time only. Using a dirty cleaning card can cause damage to the rollers. The heat roller provides the heat used during the retransfer process.
Cleaning the printer Magnetic head Tips –Magnetic head cleaning card • 34 Replace the magnetic head cleaning card when it becomes dirty. Using a dirty magnetic head cleaning card can damage the magnetic head. When printing magnetic stripe cards, the magnetic head should be cleaned every 1,000 cards. If you are not using magnetic stripe cards, the magnetic head does not require cleaning. 1 Move the RL90 laminator (if installed) away from the printer to avoid a card jam during the cleaning process.
Cleaning the printer Thermal head Tips – Thermal head • • Do not use metal or other abrasive materials to clean the thermal head. The thermal head can break if touched with an electrostatic charge. Discharge youself by touching the printer frame before cleaning the thermal head. The thermal head works should be cleaned once every ten rolls of retransfer film. 1 Slide the door latch to the right and open the printer door.
Cleaning the laminator Cleaning the laminator Most card jams are caused by dirty rollers. Clean the laminator at the same time that you clean the printer. If you are using the laminator as a stand-alone unit, clean the laminator every 1,000 cards. Run a cleaning card Tips – Laminator cleaning card • When the heat roller is at operating temperature, “HR is too hot” is displayed on the LCD display. Turn power OFF and allow unit to cool for approximately 30 minutes before starting the cleaning sequence.
Cleaning the laminator Cleaning the laminator cartridge The laminator cartridge can collect debris and dust during lamination and supply loading. Clean the cartridge every 1,000 cards. 1 2 3 4 5 Open the laminator door by pulling the top of the door toward you. Press the laminator cartridge eject button to remove the laminator cartridge. Remove the supply and take-up spools if present. Clean the two cartridge guide shafts and the four metal guides with a lint free cloth and ethanol.
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Messages and error recovery This chapter provides information to help you respond to the printer and laminator messages and explains how to recover from an error.
Printer error recovery Printer error recovery The printer’s LCD panel background color changes to red when the printer has an error. The LCD panel displays text that describes the error that has happened. Hopper jam If a card jams in the card hopper section, “Jam (Hopper)” will be displayed on the LCD panel. To remove the jammed card: 1 Pull the card hopper out and lift it slightly to remove it. 2 Remove the jammed cards: — If you can reach the jammed card, pull it out.
Printer error recovery Turnover jam Tips – Turnover jam • Some internal parts may be hot. Wear a glove when rotating the turnover table. If a card jams in the card turnover section, “Jam (Turnover)” will be displayed on the LCD panel. To remove the jammed card: 1 Slide the door latch to the right and open the printer door. 2 Press the ink ribbon cartridge eject button and remove the ink ribbon cartridge. 3 Remove the jammed card. — If you can reach the jammed card, pull it out.
Printer error recovery Retransfer section jam Tips – Retransfer jam • Some internal parts may be hot. Be careful when removing a jammed card. If card jams in the retransfer section, “Jam (Transfer)” will be displayed on the LCD panel. To remove the jammed card: 1 Slide the door latch to the right and open the printer door. 2 Press the retransfer film cartridge eject button and remove the retransfer film cartridge.
Printer error recovery Mending broken ink ribbon or retransfer film If the ink ribbon or retransfer film breaks, “Media Broken” will be displayed on the LCD panel. Broken ink ribbon is shown in the following example; repairing broken retransfer film follows the same steps. 1 Slide the door latch to the right and open the printer door. 2 Remove the cartridge by pressing the cartridge eject button. 3 Trim the ends of the broken portions evenly.
Printer error recovery Bend remedy Single-sided printing can cause the card to warp depending on the type of cards you use. Use the bend remedy Temp Level settings to correct the condition and use the Speed settings to fine tune the adjustment. Bend remedy printer settings Tips –Bend Remedy • • • You must initialize the printer by pressing the RESET and then the ENTER key. Settings will not be saved if the printer is not initialized.
Printer error recovery Bend remedy laminator settings When the laminated card warps concave, the printer bend remedy settings should be effective in correcting the problem. See Bend remedy printer settings on the previous page. If the laminated card warps convex, set the printer’s Bend Remedy> Temp Level to Off and set the laminator’s Card Fan to one of five settings. Set the printer’s Bend Remedy>Temp Level to Off when laminating cards that have been printed on both sides.
Printer error recovery Printer LCD messages LCD Message Possible Cause Solution Please, Power Off The power must be turned off to initialize the printer. Turn the power switch off and then on again. Please Remove Media Cassette Cleaning cannot start when the retransfer film cartridge is in the printer. Remove the retransfer film cartridge, press RESET and then ENTER, and start the cleaning again. HR is too hot Cleaning cannot start because the temperature of the heat roller is too high.
Printer error recovery LCD Message Possible Cause Solution Media Broken The retransfer film is broken. 1 Repair the retransfer film as described in “Mending broken ink ribbon or retransfer film” on page 43. 2 Press RESET, and then ENTER to initialize the printer one ribbon panel. Media Search The printer is searching for the retransfer film. Press RESET, and then ENTER to reset the retransfer film. Call for service if the problem persists. Media Run Out The retransfer film has run out.
Printer error recovery LCD Message Possible Cause Solution No Cassette The ink ribbon or retransfer film cartridge is not installed. 1 Install the cartridge(s) in printer. 2 Initialize the ink ribbon as described in “Initialize the ink ribbon” on page 16. 3 Initialize the retransfer film as described in “Initialize the retransfer film” on page 17. Hardware There is a hardware error. Turn the power switch off and then on again. Call for service if the problem persists.
Printer error recovery LCD Message Possible Cause Solution EXT Unconnected An external device, such as the optional laminator, is not working. 1 Check that the laminator’s power switch is on. 2 Make sure that the cable connecting the laminator to the printer is plugged in securely. 3 Turn the printer and optional laminator power switches off and then on again. 4 Call for service if the problem persists. MG Read Magnetic card reading error.
Laminator error recovery Laminator error recovery The laminator’s LCD panel displays the type of error that has happened. Card jam Tips – Laminator card jam 50 • Make sure that the card stacker is not blocking the card discharge slot. • The area around the heat roller is very hot. Be careful when removing a jammed card. The laminator’s LCD panel displays the location of the card jam: Card Jam (In), Card Jam (Middle), or Card Jam (Out). Use the following steps to remove card jams.
Laminator error recovery 6 Inspect the cartridge: — If the material on the cartridge is in one piece: — Turn the cartridge takeup knob clockwise until all damaged material is wound neatly on the take-up spool. — If the material is split or broken: — Trim the ends of the broken portions evenly. — Align the end of the supply material with the take-up spool and apply tape to secure. — Turn the material onto the take-up spool until the mended portion is wound two or three turns.
Laminator error recovery Laminator LCD messages LCD Message Possible Cause Solution Please Power OFF To initialize this unit, the power must be switched off once. Turn the laminator’s power switch off, and then back on to initialize the laminator. Please Reset Displayed when Reset is necessary after changing the settings. Press the RESET/ and then the ENTER key to initialize the laminator. Please check inside The power was switched off during lamination.
Laminator error recovery LCD Message Possible Cause Solution Heater Err The heater temperature does not increase. Check that the voltage inlet switch, located on the back of the laminator, is in the proper position for the input voltage. Contact your service provider if this does not correct the condition. HR Overheat Heat roller temperature is too high. Turn the unit off and contact your service provider before powering back on. Temp Sensor The heat roller temperature sensor is not working.
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Supplies This section outlines the recommended supplies to use with the Datacard® RP90 card printer and the Datacard® RL90 card laminator.
Ink ribbon, retransfer film, and laminator material Ink ribbon Color print ribbons are designed for full-color card printing. The ribbons use the following color panels: Y=yellow, M=magenta, C=cyan/blue, and K=black. The following ink ribbons are available: YMCK 564356-001 (Prints up to 1,000 cards per roll.) YMCKK 564356-002 (Prints up to 1,000 cards per roll.) Use when printing two-sided cards; full color on one side and black only on the other side.
Card size Use CR-80 size cards with the following nominal dimensions: Length 3.375 inches 85.60 mm Width 2.125 inches 53.98 mm Thickness 0.010 or 0.030 inches 0.25 or 0.762 mm 0.030 is the printer’s default setting. Contact your service provider before using 0.010 thick cards. Card material For best results, use cards of the following types: • PVC • PET • PET-G • Polycarbonates • ABS Cleaning supplies The printer uses the following cleaning supplies.
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Site requirements This section describes the operating environment recommended for your Datacard® RP90 card printer and Datacard® RL90 card laminator.
Site guidelines When choosing a site for the printer and its supplies, consider these guidelines: Tips – Site selection • Keep all dust, dirt, food, liquids, etc. away from the printer at all times. • Avoid locating the equipment in dirty or dusty environments. Do not use supplies or cards that have been dropped on the floor or have otherwise become contaminated. • Keep paper and foreign materials off the printer. • Do not place in areas susceptible to strong vibration or shock.
Ventilation clearance To ensure proper ventilation to the printer and laminator, maintain minimum clearance distances as shown. Sides: 8” (20mm) Back: 4” (10mm) • Keep paper and foreign materials off the printer. • Place the printer on a stable platform • Do not place in areas susceptible to strong vibration or shock. • Keep all dust, dirt, food, liquids, etc. away from the printer at all times.
Printer specifications Recording method: Sublimation type retransfer Feed format: Automatic feed Recording density: 300 dpi Expression gradation:256 gradations for each color Printing time: 29 sec. (single sided, excluding data transfer time) Interface: USB 2.
Laminator specifications Tips – Electrical • Check that the red INLET switch, located on the back of the laminator, is set for your input voltage. RP90 and RL90 User Guide Transfer method Halogen lamp built-in heat roller method Transfer time 20 seconds. The time varies according to settings.
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Compliance (FCC) This section describes the regulatory compliance of the Datacard® RP90 printer and the Datacard® RL 90 laminator.
Regulatory compliance Regulatory compliance Notice for USA (FCC notice) This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with this instruction manual, it may interfere with radio communications. This equipment has been tested and found to be within the limits for Class B computing devices, pursuant to Subpart J of Part 15 of FCC rules, designed to provide reasonable protection against radio interference in a commercial environment.
Index A about the laminator 5 the printer 2 this manual 1 C call for assistance 1 card bracket 8 cleaning card feed roller 33 hopper 8 loading 8 printing 18 run a laminator cleaning card 36 specifications 56 stacker 5 thickness 57 card jam hopper 40 laminator 50 retransfer 42 turnover 41 cartridge cleaning laminator cartridge 37 ink ribbon 3, 9 laminator 5 remove ink ribbon cartridge 9 remove laminator cartridge 11 remove retransfer film 10 retransfer film 3, 10 cleaning card cleaning roller 32 card feed ro
P patch initialize 17 load 11 plug USB cable 4 port printer 5 USB 4 power laminator inlet selection switch 63 laminator power receptacle 5 laminator switch 5 power on the laminator 14 power on the printer 15 printer power receptacle 4 preferences print 22 print cards 16 color settings 19 encode 19 from PC application 19 preferences 22 properities 19 using ID software 18 printer LCD panel 46 messages 46 port 5 power on 15 specifications 62 the back 4 the inside 3 the outside 2 printing cards 18 R retransfer
11111 Bren Road West Minnetonka, MN 55343-9015 952.933.1223 952.933.7971 FAX www.datacard.com © 2005 DataCard Corporation. All rights reserved. June 2005 564774-001 Rev.
