ASTRO AstroJet 2000 Installation, Operating, And Parts Manual

ASTRO

AstroJet 2000

High-Speed Inkjet Printer

Installation, Operating, and Parts Manual

REQUIREMENTS

1. An IBM or Compatible Pentium 100 Megahertz PC or better.

2. Windows 95 or 98 installed.

3. A minimum of 10 Megabytes of free hard disk space.

4. At least 16 Megabytes of RAM.

5. A 2X CD ROM or better.

6. An 800 X 600 SVGA Monitor or better.

7. Parallel (Centronics) printer cable, no longer than 6 feet.

8. The Parallel Port must be set to the EPP (Enhanced Parallel Port) setting in the
CMOS of the computer.

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY
RULES SHOULD BE OBSERVED WHEN OPERATING THE ASTROJET 2000 SYSTEM.

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

1. Keep hands, hair, and clothing clear of rollers and other moving parts.

2. Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance not covered in this manual.

3. Turn power off, including conveyor when not in use.

4. Keep this manual with the printer for future reference.

5. If you have any questions contact your local Astro Machine Corporation Distributor.

CAUTION

THIS EQUIPMENT MUST BE CONNECTED TO

A PROPERLY GROUNDED OUTLET. FAILURE

TO DO SO CAN CAUSE ELECTRICAL SHOCK!

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 inac curacies contained herein.

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 – Introduction 1
Section 2 – Getting Acquainted 3

Components 3
Feeder Section 4
Printer Section 4
Key Pad Definitions 5
Operator Display Screen and Menu 7

Section 3 – Installation and Setup 9

Choose a Location 9
Install the Inkjet Cartridge 9
Plug in the AstroJet 2000 10
Setting up the AstroJet 2000 10
Install Software on the Computer 11

Section 4 – Operating the AstroJet 2000 13

Software Tutorial 13
Bundle and Bag Break 25
Running a Job 26
Printing Tips 28
Databases 29

Section 5 – Maintenance 33

The Inkjet Cartridge 33
Jams in the AstroJet 2000 Printer 36
Cleaning 36

Section 6 – Trouble Shooting Guide 39

Inkjet Cartridges 39
AstroJet 2000 Printer 40
AstroJet 2000 Software 41

Appendices 43

Specifications 43
Supplies and Optional Hardware 44

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Notes

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Section 1 – Introduction

Section 1, Introduction, describes how this manual is arranged. The manual covers the
AstroJet 2000.

Section 2, Getting Acquainted, introduces the AstroJet 2000 System and describes the
major components, controls, indicators, and important areas with which the user or operator
should be familiar.

Section 3, Installation and Setup, describes how to install the software and get the
AstroJet 2000 System ready for printing.

Section 4, Operating the AstroJet 2000, describes how to set up the AstroJet 2000
System and Software to run a particular addressing job.

Section 5, Operator Maintenance, shows how to replace inkjet cartridges, how to safely
and quickly clear paper jams, and how to care for your AstroJet 2000. Also, covered in this
section are tips and suggestions that will help you increase efficiency and avoid problems.

Section 6, Trouble Shooting Guide; gives advice on how to remedy problems that may
occur during use of the AstroJet 2000.

Appendices, is where important but infrequently used information is presented. The
appendices are arranged as follows:

Appendix A, Specifications, lists the more important AstroJet 2000 characteristics,
e.g., electrical, physical, et c.

Appendix B, Supplies and Optional Hardware, presents a list of supplies for the
AstroJet 2000 System and optional equipment which will further enhance the

operation of the AstroJet 2000.

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Notes

2

Section 2 – Getting Acquainted

The AstroJet 2000 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 30,000 postcard (3.5 X 5.5 inch) mail
pieces per hour. The AstroJet 2000 has its own built in top loading feeder.

Before getting into the operation of the AstroJet 2000, there is some basic information
necessary for its efficient and problem-free use.

To understand and operate the trouble free AstroJet 2000 System lets look at the two main
areas on the printer.

1. Components

2. Operator Display Screen and Menu

Components

The main areas of the AstroJet 2000 printer are shown in the following drawing. These
areas are described in the paragraphs that follow.

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Feeder Section

The media to be printed and addressed is loaded into the feeder section of the AstroJet

2000. It is fed into the printer section as required at the speed selected by the operator from

the AstroJet 2000 Software Control Panel. The feeder is adjustable for a wide variety of
media.

Printer Section

The Printer is the most important part of the AstroJet 2000. It is here that the address and
other information are printed on the media. Two important features of the printer that you
should become familiar with are:

• The Control Panel

• The Medial Thickness Adjustment

The Control Panel

The control panel is on the front of the printer and contains the controls and indicators
(described in the following table) used to set up and operate the AstroJet 2000.

The Media Thickness Adjustment

The Media Thickness Adjustment is to the left of the ON LINE button on the control panel. It
adjusts for media thickness and is turned counterclockwise for thin media, and clockwise for
thick media.

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Keypad Definitions

CONTROL / INDICATOR DESCRIPTION

OPERATOR DISPLAY Indicates AstroJet 2000 status including menus

ON LINE When this indicator button is lit, the AstroJet 2000

PREVIOUS When in menu mode, will scroll to the previous

NEXT When in menu mode, will scroll to the previous

SELECT/FEED Locks and unlocks selection when in the menu

and error messages. Any display readout
indicates that the unit is ON.

is ready to accept data from your computer and
begin printing. Turns the printer on and off line.

selection. When in select mode, will scroll
through choices.

selection. When in select mode, will scroll
through choices.

mode. In the operational mode it starts and stops

the feeder.
TEST NON FUNCTIONING.
RESET NON FUNCTIONING.
STANDBY Toggles the printer between the ON LINE and

STANDBY modes.

Interface and Power Panel

While facing the control panel of the AstroJet 2000, the power panel can be found on the
right of the machine. It contains the main power switch, fuse, power cord receptacle, circuit
breaker, an d accessory plug. At the rear of the printer you will find the Centronics parallel
port.

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Printhead Carriage

The AstroJet 2000 has five printheads. The heads are arranged in the following
configuration:

Head 1 is on a separate rail and can be positioned between the other two banks of heads.
Heads 2 and 3 are banked together as are heads 4 and 5. These heads share the same

rail assembly.
The AstroJet 2000 Layout software shows the position of the heads and how they are

banked together. For more information on this feature, please check Section 4 Operating
the AstroJet 2000 or the AstroJet 2000 software help program.

You can move the various printing banks from side to side to position the information
properly on the media with the following restrictions:

Head 1 prints a band 1/2” wide and may be positioned anywhere within a range of 9-3/8” on
the media. It can be positioned next to and stitched to Head 2 or Head 4 to form a printing
band 1-1/2” wide. It should not be positioned next to Head 3 or Head 5, as the exit rollers
will cause tracking on the printing from those respective heads.

Heads 2 and 3 and Heads 4 and 5 form a continuous printing bank of 1” each. The
maximum distance that these two banks can be placed apart is 9-3/8”. The minimum
distance they can be placed with respect to each other is 1-3/4”. When the banks are
placed that distance from each other Head 1 can be placed between them. It is
recommended that Head 1 be placed as close to Head 4 under these circumstances if a 1­1/2” prin ting width is required.

A minimum of a 1/4” margin should be left at the top and bottom of the media to insure good
feeding and print quality. In addition a 1/4” margin should be left at the leading and trailing
edges of the media.

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Media Sensor

The media sensor is located behind the front feed plate just before the printhead carriage. It
senses the leading edge of the media and communicates this to the software. It is very
important that the media sensor be kept clean.

Operator Display Screen and Menu

When you first turn on the AstroJet 2000, you see the AstroJet 2000 welcome screen, and
the STANDBY key is lit.

MENU

To access the Menu press the STANDBY key to put the printer in the on line mode and then
press the ON LINE key to take the print off line. This action will place the AstroJet 2000 in
the MENU mode and permit access to the following settings and adjustments:

• Left Margin Setting

• Purge

• Counter

• Print Speed

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Notes

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Section 3 – Installation and Setup

Before using the AstroJet 2000 Printer for the first time, the following procedures must be
performed:

• Choose a location for the AstroJet 2000 Printer

• Install the inkjet cartridges

• Plug in the AstroJet 2000

• Set up the AstroJet 2000

• Install the AstroJet 2000 software

• Set up the transport

• Adjust for media thickness

• Position the printed output on the media

Choose a Location

Ø The AstroJet 2000 should be attached to the computer with a parallel printer

cable not more than 6 feet in length.

Ø Use a grounded electrical outlet. DO NOT USE AN ADA PTER PLUG!
Ø Do not use outlets that are controlled by wall switches.
Ø Do not use an outlet that shares the same circuit with large electrical machines

or appliances.

Ø Protect the AstroJet 2000 from excessive heat, dust, and moisture – avoid

placing it in direct sunlight.

Install the Inkjet Cartridges

NOTE: For optimum image quality during the run, refer to Cleaning the Printhead on page

34.
HP 51645A Inkjet Cartridges

The AstroJet 2000 can be equipped with 5 inkjet cartridges to give a total printing area of 2
1/2 inches. 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 vertical brackets mounted on the inkjet
cartridge holder.

• With the cartridge’s gold printhead pointing toward the rear of the unit and while
holding it vertically, slide the bottom edge of the cartridge down along the front of
the bracket until it slides partly into place.

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• At this point press the upper part of the cartridge toward the bracket until it clicks
completely into place under the metal spring secured to the bracket. (See the
diagram below.)

• Repeat the above for the remaining cartridges.

Plug in the AstroJet 2000

Make sure that the main power switch of the AstroJet 2000 Printer is in the OFF position.

1. Connect one end of the power cord to the rear of the AstroJet 2000 in the
corresponding receptacle.

2. Plug the other end into a 120-Volt AC, 60 Hz. Grounded outlet.

CAUTION

DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT
THE ASTROJET 2000 PRINTER TO THE WALL RECEPTACLE!

Set up the AstroJet 2000

Connect the Printer

In order for your computer and the AstroJet 2000 to work toget her, you will need to connect
them with a parallel cable. The cable is connected between the parallel port on the

computer and the printer. The cable used to connect the AstroJet 2000 to the computer

must not exceed 6 feet long.

Set up the Feeder

NOTE: The AstroJet 2000 is supplied with two types of sheet separators. A soft tip which is
installed on the unit when you receive it is for use with standard 20 # paper and a hard tip
for thicker media. Refer to the drawing below for the location of the separator tips. To
change them release the separator-locking lever on the left side of the feeder and lower the
separators. Remove the screw attaching the tip to the separator. Remove the existing

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separator and install the new one. Take care not to loose the mounting screw in the
machine.

The following steps will assist you in setting the feeder portion of the AstroJet 2000:

1. Place one piece of media on the feeder table move the side guides out to their extreme
open position. Release the separator-locking lever located on the left side of the feeder
and raise the separators to their up and locked position.

2. There are four separators on the feeder. Use the two center separators for narrow
media and the two end separators for wide media. Place the media under the
separators and lower the separators so that they rest on the media.

3. Move the locking lever up to lock the separators in place.

4. Adjust the side guides to the width of the media and set the back guide so that it just
touches the back of the media.

5. Turn the AstroJet 2000 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 to check the media feed. It may be necessary to adjust
the MEDIA THICKNESS control to optimize the print quality

6. Press the STAND BY switch then press the SELECT/FEED switch, to test feed media.

Install the Software on the Computer

The computer that is supplied with your AstroJet 2000 System is optimized for efficient,
trouble free operation. It is equipped with a network card (10-base T) to enable you to
connect the AstroJet 2000 System to your existing network. Contact your system manager
or deal er for installation

AstroJet 2000 Software Installation

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

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

2. 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.

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

3. Click on “Install Printer Software” and then click on the AstroJet Printer model you wish
to install. Follow the instructions on screen. Use default settings only.

Note: If the message “Setup Can Not Execute the Following Program:

C:\ProgramFiles\Astrojet III\DeReg.exe” or ”The following file is in use and can not be
updated” appears, click on Cancel button and continue with the installation.

4. If this is a new printer installation (not a software update) skip #6. Your software and
firmware are installed and configured.

5. If this is software and firmware update you must download new bios to the printer.
Connect printer to the computer and turn it on. Open AstroJet Control Panel and click on
Advanced… button then Update BIOS button. Follow instructions on screen.

6. Be sure to fill out and mail registration sheet to insure that you will be notified of all
updates to the software and firmware.

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Section 4 – Operating the AstroJet 2000

Once the AstroJet 2000 software has been installed on the computer and the AstroJet 2000
printer has been supplied with media and ink cartridges, it is ready to print. Using your
existing database, you create a Layout and Job files with the AstroJet 2000 software. The
computer sends the job to the AstroJet 2000 printer. The AstroJet 2000 then prints the Job
with both the addresses and other information you input in the layout.

This section explains how the AstroJet 2000 System is used and is divided into five main
categories:

• Software Tutorial

• Starting Up

• Preparing a Job

• Running a Job

• Printing Tips

Software Tutorial

Description of the Software

The following is a brief tutorial on how to use the AstroJet Printer Software. A more detailed
description of the various parts of the software may be found in the AstroJet “Help” menu
that accompanies the software. 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 hel p 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.

The AstroJet III folder was placed in your Program Files. This is the place where all of the
AstroJet software resides. The AstroJet Layout Editor, AstroJet Control Panel and Help files
are located in this folder along with the AccuJet Data folder. The AccuJet Data folder
contains several additional folders. These folders contain all of the information required by
the AstroJet Printer Software to create and run the job. The file structure is illustrated below:

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1 AstroJet III
1 AccuJet Data

0 Bios
0 Databases
0 Fonts

0 Jobs

0 Logos

0 Projects

The latest version of the system Bios is stored here.
This folder is used to store your databases.
When a job is printed from the AstroJet Control Panel

the fonts and logos used for that job are rendered in a
format that the AstroJet Image Bl aster Printer can use.
These rendered fonts and logos are stored in this folder
for future use when the job is run again.

The Jobs folder shows information about the job such as
total number of records, the template used to layout the
job, resolution, and last record processed.

The Logos folder can be used to store any logos in
Windows .BMP format that are used with the job.

This folder stores all of the information necessary for the
software to format and run the job.

The AstroJet Layout Editor is used to create the job. The AstroJet Control Panel is used to
send the job you created to the AstroJet Printer. All jobs are designed in the AstroJet Layout
Editor. This is where we will begin with this tutorial.

Starting the Software

Double click on the AstroJet Layout Editor icon to open the program and we will begin.
The first screen that appears is the

“Welcome to the AstroJet Layout Editor”
screen. There are three choices,
"Create a new template?", "Modify an
existing template?”, and “Modify an
existing template with a replacement
database?”. Click on the “Create a new
template?” and then click on the Next>>

button.
The “Layout Wizard – Select Database”

screen will appear. Click Next>> to
continue. The “Open” window is used to search and select the database. The

11 Databases folder in the AstroJet software is the default. You should store your

databases in this folder. Select the database type from the drop down menu. Next, select
the appropriate database and click Open to open the database. For more information on

databases and how to prepare them for the AstroJet refer to DATABASES at the end of this
section.

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Move 1 Backward Move 1 Forward

Record Position Record Number

The Wizard will switch to the “Database View – (file name)”. The first record of the
database will be displayed. There is a series of arrows just below the record. These can be
used to step through the records as follows:

Move 10 Backward Move 10 Forward
Move 10X Backward Move 10X Forward
Move to First Record Move to Last Record

Click Next>> and the “Layout Wizard – Stock Properties” window will open. Select the size
and/or type of stock that y ou will be

printing on. There are many standard
envelopes available. Select one by
using the drop down menu next to
Standard or select Custom and enter

the Width and Length of the piece.
You may save the custom size by
giving it a name and clicking on Save
As…. When you have completed this
step, click Finish. The “Layout Editor

– Untitled” screen will appear.
When the software was installed on the computer, the printing banks were set up according

to the AstroJet 2000’s configuration. The white lines in the display represent the print
cartridges and how they are positioned in the printer. The AstroJet 2000 has five print
cartridges. The print cartridges are arranged on two sets of rails as follows:

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