Hasler HJ 3630 User manual

Mailing Systems
And Solutions HASLER
America’s better choice ®
Operating Guide
HJ 3630 Printing System

Productspresentedinthisguideareconformto
requirements of directives nbr 2006/42/EG
and 2004/108/EG.
Hasler has implemented a program for the
recycling of worn machines and machines at
the end of their lifetime. Contribute in a res-
ponsible way to the environmental protection
by consulting your retailer internet site, or
by contacting him. He will inform you of the
collection and treatment processes of these
machines.

User Manual Version 3.1 3
Copyright
© Copyright 2011
All rights reserved. No part of this manual may be reproduced or transmitted in any form or
by any means, copied onto electronic media or translated into any language without the
manufacturer's express written permission.
The manufacturer is not liable for any damage resulting either from incorrect use or from
repairs and modifications carried out by a third unauthorized party. This manual was
produced with great care. However, liability for any errors which it may contain is excluded.
The manufacturer reserves the right to make any technical or design changes to the
equipment during the development process. All specified values are purely nominal.
Consequently, any legal claims made on the basis of this manual cannot be enforced.
The manufacturer is not liable for any damage or disturbance resulting from the use of
options or accessories which are not original products or do not have the express approval
of the manufacturer.
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Brands:
HP is a registered brand name of the Hewlett-Packard Company.
Microsoft and Windows are registered brand names of the Microsoft Corporation.
FlexMail is a registered brand name of Flex Systems B.V.
Bulk Mailer is a registered brand name of Satori Software Inc.
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Revision level
Version Change description Released
3.0 New document for graphic display and
firmware version 4.7 November 2010
3.1 •Added descriptions for new USB 2.0
and TCP/IP interface
•Changed description to firmware
version 4.8
•Added Device Class A note
•Corrected description for emergency
stop interface “EXTERN”
April 2011

4 User Manual Version 3.1
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a
Table of Contents
1Introduction .............................................................................11
1.1 Pictograms ............................................................................11
1.2 Notes for use of this manual.....................................................11
1.3 Terms and abbreviations .........................................................12
1.4 System requirements..............................................................12
2Safety notes .............................................................................13
2.1 General safety notes...............................................................13
2.2 Ink safety notice.....................................................................15
2.3 Location of the printer.............................................................15
2.4 Disposal ................................................................................15
3Scope of delivery and assembly................................................16
3.1 Scope of delivery....................................................................16
3.2 Delivery ................................................................................16
3.3 Device overview .....................................................................18
3.4 Assembly ..............................................................................19
3.4.1 Connecting the power cable................................................ 19
3.4.2 How to mount the Paper Guide Kit ....................................... 20
3.4.3 Plug in the strapping plugs of the emergency stop system....... 20
3.4.4 FD-13/FD-15/ Feeder (optional) .......................................... 20
4Description of device................................................................21
4.1 Application range....................................................................21
4.2 Description of functions...........................................................21
4.3 The Operator Panel.................................................................22
4.3.1 Key panel......................................................................... 23
4.3.2 Main Display..................................................................... 27
4.4 Interfaces..............................................................................30
4.5 Emergency stop connection......................................................32
4.5.1 Stand-alone operation........................................................ 32
4.5.2 Operation with one additional Hasler device........................ 32
4.5.3 Operation with several additional Hasler devices ................. 32
4.5.4 Operation with other, non-Hasler devices ........................... 33
4.5.5 How to activate the emergency stop function ........................ 33
5Initial start-up of the device.....................................................34

User Manual Version 3.1 5
5.1 How to power-on the device.....................................................34
5.2 How to install the ink cartridges ...............................................35
5.3 How to adjust the printer to the material thickness .....................36
5.4 How to position the material (print media).................................37
5.4.1 How to position the material on the transport belts.................37
5.4.2 How to set the Offset Paper value ........................................39
5.5 How to adjust the paper guide kit.............................................40
5.6 Width and height measurement of the print media......................40
5.7 How to set the print direction (orientation).................................41
5.8 How to perform a test print......................................................41
6Printer menu (firmware V4.8).................................................. 43
7How to connect the printer to the PC ..................................... 108
7.1 How to install the printer driver.............................................. 108
7.1.1 Windows XP and Windows Vista ......................................... 108
7.1.2 Windows 7...................................................................... 109
7.2 How to use the USB interface................................................. 112
7.3 How to use the Ethernet interface........................................... 112
7.3.1 Adding a TCP/IP port to a printer driver .............................. 113
7.3.2 Connecting the printer to a local area network ..................... 115
7.3.3 Direct Ethernet connection between the printer and the PC.... 118
8Service ................................................................................... 121
8.1 Maintenance and support....................................................... 121
8.1.1 How to clean the printer ................................................... 121
8.1.2 How to clean an ink cartridge ............................................ 122
8.1.3 How to clean the pen board contacts .................................. 123
8.1.4 How to clean the service station......................................... 125
8.2 Troubleshooting ................................................................... 128
8.2.1 The device cannot be turned on ......................................... 128
8.2.2 No or only very weak printout with new ink cartridges........... 128
8.2.3 Line of ink dots visible on material ..................................... 128
8.2.4 Printed elements positioned incorrectly ............................... 129
8.2.5 Corner of material stands up ............................................. 129
8.2.6 Ink on transport belt after test print ................................... 130
8.2.7 Emergency system cannot be released................................ 130
8.2.8 The printer doesn't detect a connected Feeder ..................... 131
8.2.9 How to proceed with a print job after an error...................... 132
8.2.10 White streaks in printed text or graphic .............................. 133

6 User Manual Version 3.1
8.2.11 White streak in printed text or graphics (in between cartridges)...
.....................................................................................134
8.2.12 The printed ink doesn’t dry on the substrate ........................135
8.2.13 How to reset the printer ....................................................135
8.3 Error Messages.....................................................................137
8.3.1 How to read an error message entry ...................................137
8.4 Warning Messages................................................................159
8.4.1 How to read a warning message entry.................................159
8.4.2 Additional Error Messages..................................................166
8.5 Technical Support.................................................................170
9Consumables and Accessories ................................................171
9.1 Consumables .......................................................................171
9.1.1 Standard inks for Hasler address printers............................171
9.1.2 Cleaning Towels ...............................................................172
9.1.3 Ink tray ..........................................................................173
9.2 Accessoires..........................................................................174
9.2.1 Stand for FD-13/FD-15 Feeder (in connection with HJ3060A
printer) .....................................................................................174
9.2.2 Tower Lamp ....................................................................175
10 Technical Specifications .........................................................176
11 Appendix ................................................................................178
11.1 How to completely remove printer drivers from Windows Vista
and Windows 7 ..........................................................................178
11.2 How to completely remove printer drivers from Windows XP and
Windows 2000 ...........................................................................179
11.3 How to use a pre-installed printer driver.............................180
11.3.1 USB connection................................................................180
11.3.2 Ethernet connection..........................................................181
11.3.3 How to identify the USB port used by the printer ..................182
11.4 How to test the Ethernet connectivity.................................183
11.4.1 Sample settings for Ethernet connection..............................185
11.5 How to create a print file..................................................187
11.6 How to update the flashware.............................................189
11.6.1 How to update the flashware..............................................189
11.7 How to connect the FD-13/FD-15 Feeder ............................192
11.8 How to adjust the FD-13/FD-15 Feeder to the medium..
....................................................................................196
11.9 Additional display texts ....................................................199

User Manual Version 3.1 7
11.10 Ink package ID number ................................................... 200
11.10.1 ID: 6030206 ................................................................... 201
11.11 Declaration of conformity ................................................. 202
12 Glossary ................................................................................. 204
13 Index ..................................................................................... 210
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8 User Manual Version 3.1
Table of Figures
Figure 1: Lifting the printer...................................................................................... 17
Figure 2: Hasler HJ3630 Overview............................................................................ 18
Figure 3: Side view ................................................................................................ 19
Figure 4: Mounting the paper guide kit...................................................................... 20
Figure 5: The operator panel ................................................................................... 22
Figure 6: Main display............................................................................................. 27
Figure 7: Interfaces................................................................................................ 30
Figure 8: Inserting the ink cartridge into the pen stall ................................................. 35
Figure 9: Lock the restraining lever .......................................................................... 35
Figure 10: Adjusting the printer to the material thickness ............................................ 37
Figure 11: Positioning of small formats...................................................................... 37
Figure 12: Positioning of larger formats..................................................................... 38
Figure 13: Correct positioning.................................................................................. 38
Figure 14: Incorrect positioning................................................................................ 39
Figure 15: Test print............................................................................................... 42
Figure 16: Keep Alive function ................................................................................. 53
Figure 17: Reference edge for print unit positioning .................................................... 54
Figure 18: Offset paper I......................................................................................... 56
Figure 19: Offset Paper II........................................................................................ 57
Figure 20: Adjustment of encoder necessary.............................................................. 59
Figure 21: Encoder Adjustment................................................................................ 59
Figure 22: Adjusted encoder.................................................................................... 60
Figure 23: PRINT GAP PATTERN ............................................................................... 60
Figure 24: Sample PRINT GAP PATTERN.................................................................... 61
Figure 25: GAP U1-U2............................................................................................. 61
Figure 26: PRINT CORR.PATT. for systems with two print units (6 cartridge positions)...... 62
Figure 27: Horizontal alignment U1-U2...................................................................... 63
Figure 28: ADJUST TOF test print ............................................................................. 65
Figure 29: Regular print / Direction Nor..................................................................... 66
Figure 30: Mirrored print / Direction Nor.................................................................... 66
Figure 31: Regular print / Direction Rev .................................................................... 67
Figure 32: Mirrored print / Direction Rev ................................................................... 67
Figure 33: Difference Nor/Rev.................................................................................. 85
Figure 34:LEFT MARGIN, transport direction............................................................... 86
Figure 35: Encoder Pattern...................................................................................... 99

User Manual Version 3.1 9
Figure 36: Simult. PrintUnits service print................................................................ 100
Figure 37: Overlapping service print ....................................................................... 100
Figure 38: Pattern A ............................................................................................. 101
Figure 39: Pattern A with defects............................................................................ 101
Figure 40: Cartridge contacts................................................................................. 102
Figure 41: Pattern B ............................................................................................. 102
Figure 42: Pattern C ............................................................................................. 103
Figure 43: Sample character set print ..................................................................... 103
Figure 44: Sample setting dump print ..................................................................... 104
Figure 45: Sample Input Buffer Dump print.............................................................. 105
Figure 46: New Hardware Wizard ........................................................................... 109
Figure 47: Recommended install procedure.............................................................. 109
Figure 48: Properties of unspecified device .............................................................. 111
Figure 49: Update the printer driver........................................................................ 111
Figure 50: Update Driver Software Wizard ............................................................... 111
Figure 51: Select the driver source ......................................................................... 111
Figure 52: Ferrite with plastic case ......................................................................... 112
Figure 53: Adding TCP/IP Port................................................................................ 113
Figure 54: TCP/IP Printer Port Wizard...................................................................... 113
Figure 55: IP address of the printer ........................................................................ 113
Figure 56: Custom settings.................................................................................... 114
Figure 57: Custom settings of printer port ............................................................... 114
Figure 58: Address printer port settings................................................................... 115
Figure 59: DHCP Table on server............................................................................ 117
Figure 60: Test of fix IP (ping test on server)........................................................... 118
Figure 61: Local Area Connection Properties............................................................. 120
Figure 62: TCP/IPv4 settings.................................................................................. 120
Figure 63: Cleaning the nozzle plate ....................................................................... 123
Figure 64: Nozzle plate and contacts....................................................................... 123
Figure 65: Pen board contacts................................................................................ 124
Figure 66: Removing the ink tray plate.................................................................... 126
Figure 67: Inserting the ink tray plate..................................................................... 126
Figure 68: Locking the ink tray plate....................................................................... 127
Figure 69: Ink dots on material.............................................................................. 128
Figure 70: Position of element on material............................................................... 129
Figure 71: White streaks in text ............................................................................. 133

10 User Manual Version 3.1
Figure 72: White streaks in between two cartridges .................................................. 134
Figure 73: New hardware detected ......................................................................... 181
Figure 74: Found New Hardware Wizard.................................................................. 181
Figure 75: Device Manager.................................................................................... 183
Figure 76: Device Properties - Details ..................................................................... 183
Figure 77: Command Prompt reply OK .................................................................... 184
Figure 78: Command Prompt reply NOT OK ............................................................. 184
Figure 79: Print dialog window............................................................................... 187
Figure 80: Print to file dialog.................................................................................. 187
Figure 81: Printer port properties ........................................................................... 188
Figure 82: Slots for feeder stand............................................................................ 193
Figure 83: Feeder stand position label..................................................................... 193
Figure 84: Feeder on stand I.................................................................................. 194
Figure 85: Feeder on stand II ................................................................................ 195
Figure 86: Serial connection between printer and feeder............................................ 195
Figure 87: Separator system ................................................................................. 197
Figure 88: Feeder adjustment I.............................................................................. 197
Figure 89: Feeder adjustment II............................................................................. 197
Figure 90: Feeder adjustment III............................................................................ 197
Figure 5: Adjusting the paper feed ramp and the slide, side view ............................... 198
Figure 6: Filing the stack with a fanned out pile, side view ........................................ 198
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User Manual Version 3.1 11
1Introduction
In order to ensure both long service life of the HJ3630 and its
components, as well as safe conditions of use, we recommend that
you read carefully and comply with the operating instructions and
safety notes. Always be aware of all warnings and notes that are
affixed to or printed on the machine itself.
All persons who are to handle this machine must also be familiar with the operating manual.
Store this manual in a safe place where it is easily accessible for future reference at any
time.
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1.1 Pictograms
General warnings
Warning of danger from electricity or electrical shock
Warning of possible fire
Information / Note indicating important information regarding
the handling of the machine.
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1.2 Notes for use of this manual
This manual is structured chronologically, and therefore ordered sequentially from the
receipt of the machine packed up to its ready-for-use state.
If you are unfamiliar with the machine, it is best to read through the manual from beginning
to end, where you can follow easy step by step instructions to allow you to fully and
correctly operate the machine.
If you are already familiar with the HJ3630, it will make things easy if you to use this
manual as a reference work.
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12 User Manual Version 3.1
1.3 Terms and abbreviations
This User Manual uses the following terms and abbreviations related to the Hasler HJ
3630:
•cartridge = Crt = C, C1, C2, C3
•print unit = Unit = U, U1, U2
A print unit always consists of three ink cartridges.
•print media width = expansion of the print media in transport direction.
•print media height = expansion of the print media across the transport direction.
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1.4 System requirements
The Hasler HJ3630 is designed to be used in connection with a PC. To connect the HJ
3630 to the PC one free USB port or one free Ethernet (TCP/IP) port is required. The PC
should be an up-to-date model and must have enough processing power and free disk space
to run the Hasler Addressing Solutions Software.
We recommend using one of the following operating systems:
•Microsoft Windows 2000 (SP4)
•Microsoft Windows XP (SP3)
•Microsoft Windows Vista (SP2) (32- or 64-bit)
•Microsoft Windows 7 (32- or 64-bit)
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User Manual Version 3.1 13
2Safety notes
Prior to initial operation, please carefully read the following instructions for the sake of both
your own safety and the printer operating safety. Always observe any warnings and
instructions directly attached to the device. Keep this manual available in order to be able to
check back at any time.
Disregarding this manual may cause
•electric shock,
•injury by being drawn into the transport belt or transport rollers,
•damage to the equipment.
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2.1 General safety notes
Caution!
Please read these notes with care.
Keep this manual for future reference.
All notes and warnings found on the machine are to be followed.
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Setting up the
machine
A safe, level position is necessary, when installing the machine.
Injuries may be caused by tipping, rolling away or falling.
The machine is to be protected from moisture.
The machine is not suitable for outdoor use.
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Electrical
Hazards
The power cable must only be connected to a socket with protective
grounding contact! The protective effect must not be compromised by
the use of an extension cable without a protective grounding
conductor. All interruptions of the protective grounding conductor,
within or outside of the machine, are prohibited.
When fuse failure occurs, electrical machine parts can still carry
voltage.
When making the connection to the mains power, be aware of the
connection values on the rating plate.
Run the power cable in such a way, that no one can trip over it. Do
not place any objects on the power cable.
When the machine is not in use over a long period of time, it should
be disconnected from the power supply in order to avoid any damage
in the event of a voltage surge.
Protect the device from moisture. When moisture enters the machine,
there is a danger of electrical shock.
Never open the machine. For reasons of electrical safety, the machine
should only be opened by authorized service personnel.
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14 User Manual Version 3.1
Operating
safety
Never put your hands inside the machine when it is running!
There is a danger that injuries can occur through being pulled in and
being crushed on the transport belt or the rotating rollers. In addition,
keep long hair and parts of loose clothing away from the machine
while it is in operation.
In order to prevent damage to the machine, only factory authorized
accessory parts should be used.
Cleaning the
machine
Prior to cleaning the machine, it should be disconnected from the
power outlet. When cleaning the machine, do not use liquid or spray
cleaners, but only a cloth dampened with water.
Additional information concerning the cleaning of the device can be
found in chapter „Maintenance and support“.
Machine
inspections
only by
authorized
Service
Partners!
In the following cases, you should unplug the machine from the
power outlet and contact an authorized service technician:
•When the power cable or its plug is worn or damaged.
•When water or other liquid has entered the device.
•When the device has been dropped/knocked over or the housing is
damaged.
•When there is a significant change in the performance of the
machine.
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Spare parts When repair work is carried out, only original spare parts or spare
parts approved by the manufacturer may be used.
Repairs Do not disassemble the machine any further than it is described in
this manual. The opening of the machine by unauthorized personnel
is not permitted. Repairs may only be carried out by authorized
service personnel.
Modification is
not permitted
For safety reasons, your own reworking and modifications to the
machine are not permitted.
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Please contact your authorized Hasler dealer or service partner, for
all questions relating to service and repair. In this way, you ensure
the operational safety of your machine.
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User Manual Version 3.1 15
2.2 Ink safety notice
Keep ink cartridges away from children. If you get into skin contact
with the ink, immediately clean off the ink under running water. In case
ink has entered your eye, immediately rinse it with plenty of water.
•The ink cartridge should not be shaken, dropped or hit against the palm or hard
surfaces.
•Install the ink cartridge immediately after removing the protective tape. The cartridge
may not be used after date of expiry!
•Do not try to open or refill a cartridge. This can damage the printer and reduce the
print quality.
•For further information regarding the cleaning of the ink cartridge, please see chapter
8.1.2, on page 118.
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2.3 Location of the printer
Be aware when installing the machine that it must stand on a smooth and level surface that
is larger than the printer.
When placing the machine, make sure that there is enough clearance around it, so that you
can access all connections easily.
The floor space for the printer must be sufficiently stable. The tipping over or falling of the
machine can lead to injuries, as well as damage to the machine.
When selecting the installation or storage location for the printer, keep in mind that it must
be protected from strong temperature and humidity changes, direct sunlight and excessive
heat.
The printer must not be subject to vibrations or shocks.
Install the printer near a power outlet, so that the power cable can be disconnected trouble-
free at all times.
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2.4 Disposal
The printer may not be disposed of in the conventional manner of household waste. Please
dispose the printer in accordance with the regulations in force.
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16 User Manual Version 3.1
3Scope of delivery and assembly
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3.1 Scope of delivery
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•1x HJ3630 printer
•1x Addressing Solution software CD-ROM
•1x power cable
•1x paper guide kit
•6x Black Dye ink cartridges
•2x Inxdinx ink cartridge box
•2x strapping plug for emergency-stop INTERN/EXTERN
•1x strapping plug for emergency-stop OUT
•1x 5-pin emergency-stop cable for external devices
•1x USB connection cable
•1x Network cable
•1x Ferrit
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3.2 Delivery
The Hasler HJ3630 is delivered in appropriate packaging so that it reaches its destination
without damage via a regular mode of transport.
Transportation and storage should be carried out in suitable condition. That means an
ambient temperature between +10°C and +31°C at 20-80% relative humidity (non-
condensing). Conditions outside of these ranges may harm the machine. Damages from
wrong transportation and storage conditions may not be visible on the packaging.
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Transportation locks and lifting of the printer
The HJ3630 is fixed to the transport box by transportation locks.
Loosen the transportation locks before you take out the printer. Do
only lift the HJ3630 at the recessed carrying handles provided for
this purpose. The device must not be lifted at the parts of the case.

User Manual Version 3.1 17
Figure 1: Lifting the printer
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If the printer has to be shipped again, please store the transportation locks and the
packaging. In case the packaging is no longer needed, please dispose it in an
environmentally suitable manner.
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Use the recessed
carrying handles
when lifting up
the device!

18 User Manual Version 3.1
3.3 Device overview
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Figure 2:Hasler HJ-3630 Overview
1 Emergency Stop button 6 Operator panel with display
2 Transparent cover with handle 7 Power input module
3 Finger protection with scale to
determine the offset paper value 8 Green emergency release button
4 Recessed carrying handle for lifting 9 Slots for feeder stand
5 Knurled wheel with scale for print
media thickness
1
4
2 3
5 6 7 8 9

User Manual Version 3.1 19
Figure 3: Side view
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3.4 Assembly
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3.4.1 Connecting the power cable
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Power cable
Attention!
The device may only be used in connection to power outlets with
integrated protective conductor (earthing)!
Make sure that the on/off switch is set to off. Plug the power cable
into the power input of the HJ3630. Connect the cable to the power
outlet.
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20 User Manual Version 3.1
3.4.2 How to mount the Paper Guide Kit
The paper guide kit supports an aligned feeding of the materials into the printer. Mount the
paper guide kit onto the Hasler HJ3630 as shown in Figure 4.
Figure 4: Mounting the paper guide kit
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3.4.3 Plug in the strapping plugs of the emergency stop system
Make sure to insert all strapping plugs into the emergency system interface according to the
setup of your print system. See chapter 4.5 Emergency stop connection, on page 30 for a
detailed explanation.
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3.4.4 FD-13/FD-15/ Feeder (optional)
For a detailed instruction on how to use the Hasler HJ3640 together with the optional
FD-13/FD-15 Feeder, please see chapter on page 190 of this manual.
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