ASTRO AstroJet 1000 Installation And Operating Manual

ASTRO

AstroJet 1000

Inkjet Printer

Installation, and Operating Manual

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER,
CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPER ATING THE ASTROJET
1000 SYSTEM.

BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND
FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND
INSTRUCTIONS:

ü Keep hands, hair, and clothing clear of rollers and other moving parts.
ü Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine

mechanisms come to a stop.

ü Always turn off the machine before making adjustments, cleaning the machine, or performing any

maintenance covered in this manual.

ü 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.

ü The power cord and wall plug is the primary means of disconnecting the machine for the power supply.
ü DO NOT use an adapter plug on the line cord or wall outlet.
ü DO NOT remove the ground pin from the line cord.
ü DO NOT route the power cord over sharp edges or trapped between furniture.
ü Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.
ü Make sure there is no strain on the power cord caused by jamming between the equipment, walls or furniture.
ü DO NOT remove covers. Covers enclose hazardous part s that should only be accessed by a qualified

service representative. Report any damage of covers to your service representative.

ü This machine requires periodic maintenance. Contact your authorized service representative for required

service schedules.

ü To prevent overheating, do not cover the vent openings.
ü 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 Astro Machine Corporation, 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 Astro Machine Corporation nor any of its agents or employees shall be responsible
for any inaccuracies contained herein.

ASTROJET is a registered trademark of Astro Machine Corp.
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 CONTENT

Section 1 – Getting Acquainted 1

The AstroJet 1000 1
The Control Panel 3

Section 2 – Installing the AstroJet 1000 5

Choose a Location 5
Connecting the AstroJet 1000 5
Installing the Inkjet Cartridges 6
Setting up the Feed 6
Installing the Software on the Computer 7

Section 3 – Software Tutorial 9

Using the AstroJet 1000 System Software 9
Setting up the Job 13
Saving the Template 18
Saving the Job 18

Section 4 – Running the Job 21

The Computer Control Panel 21
Running a Job 23
Printer Settings 24
Types of Media 26
Databases 27
Searching for a Record 27
Advanced Features 28

Section 5 – Maintenance 33

The Inkjet Cartridge 33
Jams in the AstroJet 1000 Printer 35
Replacing the Sheet Separators 35
Cleaning 36

Section 6 – Trouble Shooting Guide 37

Inkjet Cartridges 37
AstroJet 1000 Printer 42
AstroJet 1000 Software 39

Appendices 41

Specifications 41
Supplies and Optional Hardware 43
Software Options 44

i

Notes

ii

Section 1 – Getting Acquainted

ASTROJET 1000

The AstroJet 1000 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.

4
1 2

3 5

CONTROL PANEL – See page 3

1

SHEET SEPARATOR LOCKING LEVER – This lever locks and releases the sheet separators

2

Item 3.
SHEET SEPARATORS – There are four sheet separators that help separate the media as it is

3

being fed. (See Setting Up the Job page 6)
SIDE GUIDES – The side guides are used to maintain side to side registration.

4

REAR-GUIDE - The rear-guide is used to hold the media against the sheet -separators for

5

proper feeding.

6 7

MOTOR CIRCUIT BREAKER – This circuit breaker protects the motor from overloads.

6

POWER RECEPTACLE – The power receptacle contains the main power switch and the fuses.

7

1

1

5

2

3 4

PRINT HEAD COVER – Shown open for illustration purposes, but should be in the closed

1

position for running.
PARALLEL PORT – The printer cable from your computer should be connected here.

2

MEDIA TRANSPORT BELTS – The media is transported under the printheads on these belts.

3

PRINTHEAD CARRIAGE – The AstroJet 1000 has four printheads. Head 1, 2, and 3 are

4

banked together on the rail. Head 4 shares the same rail, but is opposite and independent of
the other heads.

You can move the two printing banks from side to side to position the information properly on
the media with the following restrictions. Heads 1, 2, and 3, print a band 1-1/2 inch wide and
may be positioned anywhere within a range of 2-1/2 inches from the Control Panel side of the
printer to 4 inches from the opposite side of the printer. Head 4 can be pos itioned to within 1­3/4 inches of head 3 and to within 2-1/2 inch of the non-operator side of the printer.

MEDIA SENSOR – The media sensor is located just before the printheads and senses the

5

media to start the printing action.

2

1 2 3 4

CONTROL PANEL

5 6 7 8 9 10

1

2

3
4
5

6

7
8

ONLINE – The indicator on this key lights when data is sent to the AstroJet
1000 and it is ready to begin printing. Turns the printer on and off line so
that menu mode can be accessed. (See Printer Settings, page 26)

PREVIOUS – When the AstroJet 1000 is in the menu mode this key will
scroll to the previous selection. When the selection is unlocked with the
select key, this key will scroll through the selections available in the selected
menu.

SELECT – In the print mode this key starts and stops the printing. In the
menu mode it locks and unlocks the selection.

ERROR INDICATOR – When RED indicates a problem with the printing
process.

RESET – This key does not function.

NEXT – When the AstroJet 1000 is in the menu mode this key will scroll to
the next selection. When the selection is unlocked with the select key, this
key will scroll through the selections available in the selected menu.

TEST – This key does not function.

STANDBY – Toggles the printer between the ON LINE and STANDBY
modes. When the AstroJet 1000 is first turned on the indicator light shows
the machine is ready to receive data.

9

10

OPERATOR DISPLAY – Indicates AstroJet 1000 status including menus
and error messages. Any display readout indicates that the unit is ON.

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.

3

Notes

4

Section 2 – Installing the AstroJet 1000

To install the AstroJet 1000 prin ter the following must be done:

• Choose a location for the AstroJet 1000 Printer

• Plug in the printer and connect it to the computer

• Install the Inkjet Cartridges

• Set up the feed on the printer

• Install the AstroJet 1000 software on the computer

• Create a job to be printed (refer to Section 4 – Software Tutorial)

Choose a Location

The AstroJet 1000 should be placed on a sturdy worktable or cabinet at least 12 inches from any
walls. Protect the AstroJet 1000 from excessive heat, dust, and moisture – avoid placing it in
direct sunlight .

Connecting the AstroJet 1000

Plugging in the Printer

Make sure that the main power switch of the AstroJet 1000 Printer is in the OFF position.

1. Connect one end of the power cord to the
rear of the AstroJet 1000 in the
corresponding receptacle.

2. Plug the other end into a 115-220 Volt AC,
50/60 Hz. Grounded outlet.

CAUTION

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.

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 AstroJet

1000 to the computer must not exceed 6 feet
long.

5

Install the Inkjet Cartridges

The AstroJet 1000 can be configured with 4 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.

NOTE: For optimum image quality during the run, refer to

"Cleaning the Printhead" on page 34.

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.

6

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 AstroJet 1000 on and then turn the
media thickness knob to set the initial print
head height as follows:

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

NOTE: These are initial settings. It may be necessary to adjust the MEDIA THICKNESS

control to optimize the print quality

6. Press the STAND BY key, and then press the SELECT key, to test feed media.

NOTE: The AstroJet 1000 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 5 –
Maintenance for instructions on how to change them.

Installing the Software on the Computer

The AstroJet 1000 is not supplied with a computer. The computer that you use with your AstroJet
1000 System should meet the following minimum requirements:

An IBM or Compatible Pentium 100 Megahertz PC or better.
Windows 95, 98, 2000 or NT installed.
A minimum of 20 Megabytes of free hard disk space.
The computer should be equipped with at least 16 Megabytes of RAM for Windows 95 and 98
(32 Megabytes of RAM required for Windows 2000 and NT).
A 2X CD ROM or better.
An 800 X 600 SVGA Monitor or better.
Parallel (Centronics) printer cable, no longer than 6 feet.
The Parallel Port must be set to the EPP (Enhanced Parallel Port) setting in the CMOS of the
computer.

AstroJet 1000 Software Version 3.3 Installation

1. Before installing the CD check that there is at least 20 megabytes of disk space available on
the computer.

2. Close all programs currently running and reboot the computer. Do not open any programs
prior to installing AstroJet software.

7

3. Install the CD in the computer. The CD should start automatically. If it does not click on the

Start button, then select Run. Type “D:\Setup.exe” (where D is the CD drive) and then click
OK.

4. The AstroJet Setup Menu will appear on your screen. It contains five options:
Install Printer Software
Read the Manuals
Browse this CD
Install Adobe Acrobat – This is version 4.0 of Adobe Acrobat for reading and printing the

Operator Manuals.
www.astromachine.com – this is a link to our web site if you are connected to the Internet.

5. Click on “Install Printer Software” and then choose the operating system that is installed on

your computer. If you are using Windows 95 refer to the instructions under “Windows 95” and
if you are using Windows 98, Windows NT4, or Windows 2000 refer to the instructions under
“W98 / NT4 / W2000”.

6. If this is a new printer installation (not a software update) go to the installation instructions for

your operating system to complete the installation. If this is a software and firmware update,
you must also download a new “BIOS” to the printer.

Windows 95

1. Insert the program CD into your CD-ROM drive. Click on “Install Printer Software”.

2. Select “Windows 95”.

3. Select “ODBC95” and follow the instructions in the windows to install “DCOM95 for Windows

95”. When this is installed Restart your computer.

4. Open the program CD again and select “Install Printer Software”, then “Windows 95”.

5. Select “AstroJet” and follow the directions in the windows . At the end of the installation you

will be asked to identify the model of your printer. Select the AstroJet 1000 and then restart
your computer.

Windows 98, NT4, or 2000

1. Insert the program CD into your CD-ROM drive. Click on “Install Printer Software”.

2. Select “W98 / NT4 / W2000” “AstroJet Setup will appear with the “Welcome: window. Follow

the instructions.

3. At the end of the installation you will be asked to identify the model of your printer. Select the

AstroJet 1000 and then restart your computer.

BIOS Installation

1. Load the AstroJet software for your printer into your computer.

2. Connect the computer to the printer and turn the printer ON.

3. Select the “AstroJet Control Panel” icon on your desktop and double click on it.

4. Select “Properties”, then select “Update BIOS”.

5. Click on the Update BIOS button. When the software completes the update check the printer’s

control panel for the new BIOS level.

NOTE: DO NOT TURN THE POWER OFF DURING THIS PROCESS.

8

Section 3 – Software Tutorial

This section assumes that the AstroJet 1000 software has been installed on the
computer and that the computer is connected to the printer. Following the
instructions below will teach you how to create a job, process that job, and in Section
4 send the job to the printer and print it . Additional information on the operation of
the software can be found in the AstroJet Help file on your computer.

Using the AstroJet 1000 System Software

This tutorial begins with a brief discussion of how the program files are arranged. It is assumed that
you have experience in navigating through Windows. If you are new to computers or are not familiar
with Windows many books are available that can help you.

The software is divided into two parts, The AstroJet Layout Editor and the AstroJet Control Panel.
When the AstroJet Printer Software was loaded on the computer, the two icons shown below were
placed on the desktop.

In addition, the AstroJet folder was placed in your Program Files folder. This is the place where all of
the AstroJet 1000 software resides. The AstroJet Layout Editor, AstroJet Control Panel and Help files
are located in this folder along with the Data folder. The Data folder contains several additional folders
one for each AstroJet Printer model. The AstroJet 1000 folder contains all of the information required
by the AstroJet 1000 Printer Software to create and run the job.

The AstroJet Layout Editor is used to create the job that is to be run. The AstroJet Control Panel is
used to send the job you created to the AstroJet 1000 Printer. All jobs are designed in the AstroJet
Layout Editor.

Double click on the AstroJet Layout Editor icon and open the program.

9

The “Layout Editor – Untitled”
screen will appear. Click on the

icon or File, then New and the
“Layout Editor – Select Database”
window will appear. Leave the
box “Does this template require a
database?” checked and click
OK.

The “Select Database” screen will
now appear. Click on the drop
down menu “Files of Type” and
select “1 UP LABELS (*TXT) ”.
Highlight “4Lines.TXT” and click on
Open to continue.

The “4Lines.txt” database is
included in the software and is
indexed.

DATABASE FILES

Before we proceed there are a few
things about the way the AstroJet
software handles databases that
should be noted. If you use a TXT
database other than the one
supplied, the software will create an
index file when you click Open from
the “Select Database window. You
will be asked if the firs t record is
used to record field names. If it is,
check the box. Then click OK.

10

CSV databases are also indexed,
but additional information about the
character that delimits the fields is
required for the software to create
the index file. Click on the
appropriate delimiter and then click

OK.

Microsoft Access *.MDB, dBase III,
IV, V, and FoxPro *.DBF files are
automatically converted to *.CSV
files with a comma delimiter. If you
make any changes to these types
of databases by upgrading or
adding information the AstroJet
software will automatically re-index
the file the next time you open the
template.

The “4Lines.txt”, database in the
software is indexed. The next
screen to appear is the “Database
View – 4lines ” window displaying
the first record in the database.

There is a series of arrows
just below the record.
These can be used to step
through the records as
shown.

NOTE: The 11 Databases folder in the AstroJet 1000 software is the default. You must store

your databases in this folder.

Click Next>> and the “Layout Wizard – Stock Properties” window will appear. For the purpose of this
tutorial we will select the standard #10 envelope. This window which is also accessible from the

11

Layout Editor screen allows you to
choose from a list of standard
envelope sizes or permits you to
create your own custom envelope
size. If you choose to create a
custom envelope size, select
custom, enter the size of the piece
in width and length, give the piece
a name in the “Save As” window
and click Save As then OK. The
new size will be saved to the list as
a Standard size for future use.

When you click on OK, the “Layout
Editor – Untitled” window will open.
You will notice that there are 8
print bands shown. The AstroJet
1000 has 4 printheads. To setup
the layout screen to match the
printer, click on Setup on the pull
down menu bar and select
Printhead. The “Print Head
Properties” window will appear.
Click on the check marks on Print
Heads 5, 6, 7, and 8 to turn the
guidelines for the heads off.

The “Layout Editor – Untitled
screen will reappear as below.
You are now ready to enter the
information and set up the job.

If you choose you may start by
selecting Open from the file menu, then Select “TemplateAJ1000FWD.AJPJT”, and click OK. Next
select Change Database and when the “***Warning***” window appears click OK. The “Select
Database” window will open. Select the database you wish to use and click OK. Immediately select
Save As… from the File menu and give the template another name. This will preserve the original
template for future use. This technique is particularly useful when Reverse Printing.

Before continuing, spend a little time exploring the “Layout Editor – Untitled” screen.
The white lines in the display represent the print cartridges and how they are positioned in the printer.

The AstroJet 1000 has four print cartridges . The print cartridges are arranged on one set of rails in the
following manner:

Printheads 1, 2, and 3 are connected together and printhead 4 is separate and facing printhead 3.
The total printing width is 2 inches, however there is always a 1 3/4-inch space between the bank of
three heads and printhead 4. This must be taken into account when setting up a job. If you wish to
place a message below the destination address line on a piece you must set up the layout for Reverse
printing. A template is provided to help you with this under “TemplateAJ1000REV.AJPJT”. Also at the
end of this sect are instructions for creating a reverse printing layout.

12

By clicking on the RED numbers to the left of the layout you can move the print band positions on the
layout.

The drop down menu bar consists of the following items:

File View Fields Setup Tools Help

Each of these menus provides choices that perform the tasks required for setting up the job. The
second line contains icons that represent the basic tasks required to set up the job. For the purpose of
this tutorial, we will use both the icon buttons and the menu bar to set up a sample job.

To the left of the media image are numbers. These correspond to the printheads and are marked with
the same numbers on the AstroJet 1000 Printer. When the numbers are in RED the print direction is
Forward and when the numbers are in BLUE the print direction is Reverse. To the right of the media
image is a line. This guideline can be moved to any point on the layout to assist you in lining up the
fields or information that you will be adding. To get all of the information to line up on a particular bank
move the line close to the position desired for the text fields and right click on the mouse while the
guideline is selected.

At the bottom of the window is the information line. It displays the database in use, the printer being
used, the ratio of the length of the piece to its height, the size of the piece in inches , and the
orientation of the print direction either forward or reverse.

Setting up the Job

It is a good idea to get into the habit of naming and saving your Layout at this point. Select File, then
Save Template As… and then type the name “SAMPLE”. Then click Save .

If you wish to change the type or size of the envelope before beginning, use the Setup menu and click
on Envelope Size or click on the Envelope Size icon on the menu bar

13

When you click on this icon
the Envelope Properties window
will open. You may choose any of
the standard envelope sizes listed
under Standard or you may select
Custom and create your own
envelope size. To do this highlight
the Width and type in the actual
width of the media, and then
highlight the Length and type in
the length of the media. You may
use any number or fraction from 3
inches up to 12 inches in width and
from 5 inches up to 14 inches in
length. To save the custom size
so that it is available for future
layouts type a unique name in the
save as box and click Save As…
Next click OK and the Layout
screen will adjust the view of the media to the size selected automatically. The illustration at right
shows a change to a 6 X 9 inch envelope.

The next step is to begin

building the job on the layout.
When you click on the “Text Field
Properties” icon the “Layout Editor
– Text Field Properties” window
will open. This window permits
you to enable up to 24 text fields of
information and/or data. One
button for each of the text fields
that will be different from the others
in the layout should be selected. If
you want to make additions or
deletions to the layout you can
click on this icon anytime during
the setup or before you run the job
to add new text fields. For the
purposes of this tutorial, we are
going to enable the first 3 text
fields. Text Field 1 will be for the database address. Text Field 2 will be for the company name in the
return address. Text Field 3 will be for an additional message.

After enabling the text fields, click OK to continue.
The software returns to the Layout Editor screen and the data

selected will be displayed at the bottom right hand corner of the
layout called the blotter area. Use the mouse to move each text
field into the general area of the layout where they will be finally
positioned as in the example below.

14