Hasler HJ500P User manual

Mailing Systems
And Solutions HASLER
America’s better choice
®
An ISO 9001 Quality System
Certified company
Operating Guide
HJ500P Inkjet Printer

Model Number ____________________
Serial Number ____________________
Dealer Phone ____________________
Hasler®, Inc.
19 Forest Parkway
Shelton, CT 06484-6140
TEL [phone]
203/926-1087
FAX [phone]
E-Mail [email protected]
Web: http://www.haslerinc.com

CUSTOMER SURVEY FORM HJ500P Operating Guide
Revision: 03/2004 Form 51019
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SAFETY PRECAUTIONS
This Equipment Presents No Problem When Used Properly. However, Certain Safety Rules
Should Be Observed When Operating The Hasler HJ500P System.
Before Using The HJ500P, You Should Read This Manual Carefully And Follow The
Recommended Procedures, Safety Warnings, And Instructions:
 Keep hands, hair, and clothing clear of rollers and other moving parts.
 Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine
mechanisms come to a stop.
 Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
 Use the power cord supplied with the machine and plug it into a properly grounded wall outlet located near
the machine and easily accessible. Failure to properly ground the machine can result in sever personal injury
and/or fire.
 The power cord and wall plug is the primary means of disconnecting the machine for the power supply.
 DO NOT use an adapter plug on the line cord or wall outlet.
 DO NOT remove the ground pin from the line cord.
 DO NOT route the power cord over sharp edges or trapped between furniture.
 Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.
 Make sure there is no strain on the power cord caused by jamming between the equipment, walls or furniture.
 DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified
service representative. Report any damage of covers to your service representative.
 This machine requires periodic maintenance. Contact your authorized service representative for required
service schedules.
 To prevent overheating, do not cover the vent openings.
 Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Hasler®, Inc. … its designated
agents, customers, and their employees. The information in this guide was obtained from
several different sources that are deemed reliable by all industry standards. To the best of our
knowledge, that information is accurate in all respects. However, neither Hasler®, Inc. nor any
of its agents or employees shall be responsible for any inaccuracies contained herein.
Hasler®, Inc is a registered trademark of Hasler Mailing Systems And Solutions.
Hewlett-Packard is a registered trademark of Hewlett-Packard Corporation.
Windows 95 and Windows 98 are registered trademarks of Microsoft Corporation.
IBM is a registered trademark of International Business Machines.
All other trademarks are the property of their respective holders.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopying, recording, or any information storage and retrieval system, without permission in writing from the Publisher.

Table of Contents
Section 1 – Getting Acquainted 1
Operator View 1
Rear View 2
The Control Panel 3
Section 2 – Installing the HJ500P 5
Choose a Location 5
Connecting the HJ500P 5
Installing the Inkjet Cartridges 6
Setting up the Feed 6
Installing the Software on the Computer 7
Section 3 – Operating The HJ500P 9
Printer Control Panel 9
Printer Driver Properties 10
Printing From Microsoft Word 14
Printing From DeskTop Mailer 16
Print Recovery After Jam 19
Section 4 – Maintenance 21
The Ink Cartridge 21
Jams In The Printer 23
Replacing The Sheet Separators 23
Replacing The Feed Rollers 24
Cleaning 25
Section 5 – Troubleshooting 27
HP Inkjet Print Cartridges 27
The Printer 28
Appendices 29
Appendix A - Specifications 29
Appendix B - Supplies and Optional Hardware 30
Index 31

Section 1 – Getting Acquainted HJ500P
Hasler®, Inc. 03/2004 Page-1
Operator View
The HJ500P is a high-speed
printing and addressing
systems that can print
addresses, bar code, return
addresses, bitmapped
graphics, and special
messages using TrueType
scaleable fonts simultaneously
on up to 20,000 postcard (3.5
X 5.5 inch) mail pieces per
hour.
1.
Safety Cover – The safety cover encloses the printheads. When raised it interrupts
the feeding of the media and stops the printer.
2.
Media Side Guides – Help guide the media to the printheads.
3.
Rear Media Guide – Holds the media against the front plate.
4.
Rear Paper Support – Holds longer media in position.
5.
Media Thickness Adjustment Knob – Is used to set the printheads at the proper
height for printing on the media.
6.
Printer LCD Display – Displays information about the status of the printer.
7.
Printer Control Panel – The keys on the printer control panel are used to operate
the printer.

Section 1 – Getting Acquainted HJ500P
Page-2 04/2004 Hasler®, Inc.
Rear View
1.
Media Thickness Control Knob – Is used to adjust the height of the printheads.
2.
Sheet Separator Locking Lever – Is used to lock the separators in place after it is
adjusted.
3.
Sheet Separator – Separates each piece of media as it is feed.
4.
USB Port – Connects the printer to your computer using your USB port.
5.
Parallel Port – Connects the printer to the parallel printer port on your computer.
6.
Main Power Switch – This switch turns the printer ON and OFF.
7.
Main Power Fuse – This fuse protects all of the electronic circuits in the printer.
8.
Power Receptacle – The power cord is plugged in here.
9.
Accessory Connector – This is to connect “future enhancements”..
10.
Motor Circuit Breaker – The circuit breaker protects the printer’s motor from
overload.

Section 1 – Getting Acquainted HJ500P
Hasler®, Inc. 04/2004 Page-3
Control Panel
1.
ON LINE key – The indicator on this key lights when data is sent to the HJ500P
and they are ready to begin printing. This key also turns the printer off line so
that the menu mode can be accessed.
2. -
key – In the menu mode this key will scroll to the previous selection.
3.
ENTER key – This key starts and stops the printing.
4.
FAULT Indicator – This indicator lights when there is a problem with the printing
process.
5.
RESET key – This key will reset the printer to its wait state.
6. +
key – When the printer is in the menu mode this key will scroll to the next
selection.
7.
MENU key – This key causes the printer to enter the menu mode where several
operator functions can be accessed.
8.
TEST PRINT key – Pressing this key will put the printer in the test mode and
send a sample copy to check the printer’s output.
9.
OPERATOR DISPLAY – Indicates the printer’s status including menus and error
messages.
10.
MEDIA THICKNESS – The knob on the right side of the control panel is used to
adjust the height of the print heads to compensate for different media thickness.
NOTE: A complete description of the functions and operation of the printer keys can be found in Section 3 –
Operating the HJ500P.

Section 1 – Getting Acquainted HJ500P
Page-4 04/2004 Hasler®, Inc.
Notes

Section 2 – Installing The HJ500P HJ500P
Hasler®, Inc. 03/2004 Page-5
Before using the printer the following must be done:
• Choose a location for the Printer
• Plug in the printer and connect it to the computer
• Install the Inkjet Cartridges
• Set up the feed on the printer
• Install the HJ500P Printer Driver and BIOS Manager software on the computer
Choose a Location
The HJ500P should be placed on a sturdy worktable or cabinet at least 12 inches from any walls. Protect the
HJ500P from excessive heat, dust, and moisture – avoid placing it in direct sunlight.
Connecting the HJ500P
Plugging in the Printer
Make sure that the main power switch of the HJ500P Printer
is in the OFF position.
1. Connect one end of the power cord to the rear of the
HJ500P in the corresponding receptacle.
2. Plug the other end into a 115 Volt AC, 60 Hz.
Grounded outlet.
Connecting to the Computer
Plug the parallel printer cable from your computer into the
rear of the printer and latch the two locking clips. The cable
used to connect the HJ500P to the computer must not
exceed 6 feet long.
NOTE: The parallel port may be used for all versions of
Windows. The USB port is used only for Windows ME, 2000,
and XP.
Do not use an adapter plug or extension cord to
connect the printer to the wall receptacle.
Do not use outlets controlled by wall switches.
Do not use an outlet that shares the same circuit
with large electrical machines or appliances.

Section 2 – Installing The HJ500P HJ500P
Page-6 03/2004 Hasler®, Inc.
Install the Inkjet Cartridges
The HJ500P can be configured with up to 5 inkjet cartridges. The cartridges are installed as follows:
• Remove the inkjet cartridge from its packaging, taking care
not to touch the copper contacts, the metal plate, or the gold
printhead. Remove the protective tape from the printhead.
• The cartridges are held in place by a latch lever mounted on
the inkjet cartridge holder. Release the lever by raising it
vertical.
• With the cartridge’s printhead pointing down, slide the
cartridge into the holder and push down and toward the
contacts in the holder.
• Make sure the cartridge is seated in the holder then close the
latch lever to secure the cartridge in the holder. Do not force
the lever into place. (See the diagram.)
• Repeat the above for the remaining cartridges.
The ink in the cartridge may be harmful if swallowed. Keep new and used
cartridges out of reach of children. Discard empty cartridges immediately.
Setting up the Feed
1. Release the separator-locking lever located on the
operator’s side of the feeder and raise the separators to
the up and locked position. Move the side guides out to
their extreme open position. Place one piece of media
in the center of the feed table.
2. There are four separators on the feeder. Use the two
center separators for narrow media and all four
separators for wide media. Place the media under the
separators and lower the separators so that they rest
on the media.
3. Rotate the locking lever up to lock the separators in
place.

Section 2 – Installing The HJ500P HJ500P
Hasler®, Inc. 03/2004 Page-7
4. Adjust the side guides to within 1/32-inch of the
media and set the back guide so that the media
is raised approximately 1/2-inch and rests on
the curve of the back guide. When running 10
inch or longer or heavy media you may have to
set the back guide so that it just touches the
back of the media.
5. Turn the HJ500P on and then turn the media
thickness knob to set the initial print head
height as follows:
NOTE: These are initial settings. It may be necessary to adjust the MEDIA THICKNESS control to optimize
the print quality
6. Press the ON LINE key, and then press the ENTER key, to test feed media.
NOTE: The HJ500P is supplied with two types of sheet separators. The hard tip, which is installed on the unit
when you receive it, is for media such as envelopes, books, and stuffed envelopes. A soft tip
separator is packed with the machine for use with single sheets of paper and plain envelopes. Refer
to Section 4 – Maintenance for instructions on how to change them.
Installing the Printer Driver
A dedicated printer driver is included with the Printer. It is installed on your computer and is used by your
applications whenever you are printing from the Printer. Follow the steps below to install the driver:
NOTE: The driver for the Printer should be installed using the steps below. It is not installed as a
standard windows driver.
1. If you have any applications running on your computer close them and restart the computer before
beginning the driver installation.
2. Install the CD in the CD drive and click on START. Then click on RUN, then type the following;
D:\Setup.exe (where D is the CD drive) Then
click OK.
3. The “Add Printer Wizard (n.nn)” window will
open., click Next>..
4. Type in your Name and Company and click
Next>.
5. Select the printer port LPT1:. Then click
Next>. The “Add Printer Wizard” will appear.
Select ASTROJET 1000P, then click Next>.
Media Thickness Dial Setting
.004” to 1/32” 0 to 2
1/32” to 1/16” 2 to 3
1/16” to 1/8” 3 to 7
1/8” to 1/4” 7 to 10

Section 2 – Installing The HJ500P HJ500P
Page-8 03/2004 Hasler®, Inc.
NOTE: Each printer has a specific driver. Select the HJ500P driver.
6. The next screen allows you to “Name Your Printer”. Unless you have another printer of the same name
on your system or network ignore this step and click Next>.
7. Click Finish to complete the installation.

Section 3 – Operating The HJ500P HJ500P
Hasler®, Inc. 03/2004 Page-9
Once the Printer Driver is installed on your computer, you are ready to start printing. This section is divided into
three parts. The first describes the function of the printer control panel. The second section describes the driver
properties and the various options available when you run a job. The third section describes how to set up a job
to print from Microsoft Word.
The Printer Driver that you installed on your computer in Section 2 should be set as the default driver. It will then
be accessible through your applications such as Microsoft Word. Other types of applications and database
management software will work in a similar manner using the HJ500P Driver.
This Section further assumes that you have setup the feed and connected the HJ500P to your computer.
Printer Control Panel
When you first turn the printer ON, the light in the TEST PRINT key lights and the display becomes active. At this
point the printer is ready to print if it is connected to your computer.
The printer control panel keys can be used to access various functions that help the operator control the printer.
These functions and their operation are as follows:
ENTER key - The ENTER key is used to start the printer printing under production situations. When the
printer is placed in any of the menu modes, the ENTER key is used to choose the options available.
TEST PRINT key - Pressing the TEST PRINT key momentarily places the printer in the test print mode. The
word “Working “appears in the lower half of the display and after a short period of time the display changes to
“Enter to feed”. Pressing the ENTER key will start the printing process and print the test print. To stop the
feeding press, ENTER again.
To restore the printer to the normal ready mode press the ON LINE key to take the printer off line and then press
and hold the RESET key until the light on the TEST PRINT key blinks. The printer is then restored to its normal
ready state.
Pressing and holding the TEST PRINT key will cause the printer to enter the “Service Menu” where the various
functions of the printer can be tested. To exit the “Service Menu” turn the printer OFF, the ON again. The service
menu is primarily used by service to diagnose problems should they occur. You can use the “+” or “-“ key to
scroll through the menu. Pressing the ENTER key will test the function. To restore the printer to its normal print
mode, turn it OFF then ON.
To check the level of the ink cartridges when you enter the Service Menu press the “-“ key and the amount of ink
remaining will appear as a percentage in the lower half of the display window.
MENU key - The MENU key is used to access the special features built into the printer. The basic features
are accessed by momentarily pressing the MENU key. Use the “+” or “-“ keys to access the features. The
features available under this mode of operation are as follows:
Clear Batch Counter – Pressing the ENTER key will clear the number in the upper right hand corner of the
display. Resetting the counter is usually performed at the start of each job. Turning OFF the printer will not
reset this counter.
Continued on the next page.

Section 3 – Operating The HJ500P HJ500P
Page-10 03/2004 Hasler®, Inc.
Purge – The purging function is useful to clear the printhead nozzles when the machine has been sitting idle
for a period of time. To activate the purge, press the ENTER key and feed media. To stop the purge press,
ENTER again.
Print Enhancement – Pressing the “+” or “-“ key will bring this message up in the display. The print
enhancement feature is used when printing to ensure that the nozzles on the printhead stay open and
prevent the loss of the descender on letters such as “y” or “q” and accent marks that do not appear in every
address. Pressing the ENTER key will turn this function ON or OFF. The function will remain as changed
until the operator changes it again. Turning the printer ON and OFF will not affect the setting.
Installing New Printheads – The printer is capable of telling you when a printhead is running low of ink. To
use this feature press the MENU key momentarily, then use the “+” or “-“ key to highlight “Enter when head
(n) is filled”. Press the ENTER key and install a new cartridge. Repeat for each cartridge you install. When
the ENTER key is pressed the display will change to “Head (n) has a new cartridge”. To check the level of
ink in the cartridges, Press and hold the TEST PRINT key until the “Service Menu” appears. Use the “+” or
“-“ key to scroll to the “Service Menu: Ink Levels, 100%100%100%”. This will show how much ink remains in
the cartridge.
NOTE: This feature only works if the cartridges remain in the original head where they were installed. If you
swap the cartridges from one head to another, the levels will not be accurate.
There is a second set of menus available in the display. To activate them press and hold the MENU key
until the “Setup Menu” appears. You can step through these items with the “+” or “-“ key.
Total Count – The total count displayed is the total number of prints that have passed through the printer. It
is non-resettable.
BIOS Version – The version of the BIOS is displayed in this menu when the “+” key is pressed once. From
time to time it may be necessary to upgrade the BIOS in the printer. When this is done, the new BIOS
version can be checked in this manner.
Bulk Ink – This feature is not used on the HJ500P. No provisions are made to install the larger cartridges.
+ / - key - In the various menu modes these keys are used to step through the options.
ON LINE key - The printer automatically goes on line and the light in the ON LINE key lights when there is
information from the computer to print. Pressing the ON LINE key during the printing operation will take the
printer off line and stop the printing. To reset the printer to its ready state, turn it off line then press and hold the
RESET key until the light in the TEST PRINT key blinks.
RESET key - The RESET key is used to clear the printer memory and return it to the wait state. This key only
functions if the printer is off line.
Printer Driver Properties
The printer driver describes to the printer how to print your job. It controls the operation of the printer and allows
you to send fixed and variable text and graphics to the printer. Within your data management software is a print
function. In that print function is a properties button. It is through the properties that you control the output of
your printer. The following describes the properties windows for the HJ500P and how to use them to customize
the output of your printer.

Section 3 – Operating The HJ500P HJ500P
Hasler®, Inc. 04/2004 Page-11
To start printing click on File, then Print. The Print window
will open. If you wish to print the job click on OK. If you wish
to use the special features built into the HJ500P drivers.
Clicking on the Properties button will open the properties
window in Windows 95, 98, NT, or ME.
If you are using Windows 2000 or XP the window on the right
will open. Clicking on Advanced will open the Options
window. In the following illustrations the windows for
Windows 95, 98, NT, and ME will be on the left. The
windows for Windows 2000 and XP will be on the right.
When the properties window opens you are presented with
several tabs in Windows 95, 98, . The following are
standard windows printer driver functions and should be left
at their defaults: Graphics, Fonts, and Device Options.
The Features and Print Heads tabs are used to setup,
change, and adjust the printer.
Features Tab
The Features Tab/ Advanced Options depending on the operating system is used to change the speed and
resolution of the Printer, to add a delay to the feed to provide separation between the pieces, and to print and
overlay with the job. The first feature is the Print Quality which has two settings. One for the Resolution of the
print quality and the second for the appropriate speed. Changing the resolution to a higher number e.g. 200 DPI
to 600 DPI will increase the quality of the image. When the resolution is changed the Belt speed (IPS) is
automatically changed to the optimum speed for the resolution selected.

Section 3 – Operating The HJ500P HJ500P
Page-12 03/2004 Hasler®, Inc.
Resolution Speeds available
150 DPI Low, Medium, Medium High, and High
200 DPI Low, Medium, and Medium High
300 DPI Low, and Medium
600 DPI Low
You can, however change the speeds to a lower speed as follows:
The Feed Delay can be used to put more space
between the pieces as they are being printed.
This will give the first piece printed more time to dry
before the next piece is printer. The adjustment
range is in 0.1-second increments. This feature
works at all speeds.
The Overlay feature is used to save time printing when you are combining a database with fixed information or
graphics. The default is “No overlay”.