ASTRO ASTROJET IMAGE BLASTER, astrojet II plus, astrojet III, astrojet III plus Installation And Operating Manual

ASTRO

ASTROJET™ IMAGE BLASTER

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 IMAGE BLASTER
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 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 CONTENTS

Section 1 – Introduction 1
Section 2 – Getting Acquainted 3

Printhead Carriage 3
Media Sensor 4
Reflective Tape 4
Media Thickness Knob 4
Bulk Ink Supply Tray 4
Control Panel 4
Interface and Power Panel 5
Encoder 6

Section 3 – Installation and Setup 7

Choosing a Location 7
Installing Image Blaster on Base 7
Installing the Encoder on Kirk-Rudy Base 8
Installing the Inkjet Cartridge 9
Plugging in the Image Blaster 11
Connecting the Image Blaster to the Computer 12
Installing the Software on the Computer 12
Adjusting the Image Blaster to the Media 13
Positioning the Printer Output on the Media 13

Section 4 – Operating the IMAGE BLASTER 15

AstroJet System Software Tutorial 15
Bundle and Bag Breaks 28
Starting up 29
Preparing a Job 29
Running a Job 30
Printing Tips 30
Databases 31

Section 5 – Maintenance 35

The Inkjet Cartridge 35
Jams in the IMAGE BLASTER Printer 39
Cleaning the IMAGE BLASTER 40

Section 6 – Trouble Shooting Guide 43

Inkjet Cartridges 43
ASTROJET Printer 45
ASTROJET Software 46

Appendices 49

Specifications 49
Supplies and Optional Hardware 50

Parts Manual 51

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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 Image Blaster Printer.

Section 2, Getting Acquainted, introduces the AstroJet Image Blaster 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 Image Blaster ready for printing.

Section 4, Operating the AstroJet Image Blaster, describes how to set up the
AstroJet Image Blaster and software to run a 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 Image Blaster.
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 Image Blaster.

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

Appendix A, Specifications, lists the more important AstroJet Image Blaster
characteristics, e.g., electrical, physical, etc.

Appendix B, Supplies and Optional Hardware, presents a list of supplies for the
AstroJet Image Blaster and optional equipment which will further enhance its
operation.

Parts Manual , is a break down of the parts in the Image Blaster.

1

Notes

2

Section 2 – Getting Acquainted

The AstroJet Image Blaster is a high -speed printer that can be mounted on many
different feeder bases. It can print addresses, bar code, return addresses, bitmapped
graphics, and special messages using TrueType scaleable fonts simultaneously at
speeds up to 30,000 postcard size (3.5 X 5.5 inch) mail pieces per hour.

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

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

Printhead Carriage

The AstroJet Image Blaster has six printhead cartridges. There are two sets of rails on
the print head carriage, each with banks of cartridges that correspond to printing areas
in the software. The printheads are arranged a follows:

Heads 2,3, and 4 are banked together and share the same rail.
Heads 5 and 6 are banked together and share the rail with head 1.
In addition to the above configuration the AstroJet Image Blaster is available with two

additional cartridges for a total of eight. How the inkjet cartridges are installed and
replaced will be covered in Section 3.

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The AstroJet Image Blaster 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 Image Blaster or the help section of the AstroJet Image Blaster
software.

You can move the various printing banks from side to side to position the information
properly on the media. There is a metal tab on each bank that shows the location and
printing area of each printhead. This feature makes setup of the AstroJet Image Blaster
quick and accurate.

Media Sensor

The media sensor senses the leading edge of the media and communicates this to the
software. It is very important that the media sensor be kept clean.

Reflective Tape

A piece of reflective tape is supplied in the Image Blaster Kit. This tape is installed on
the feeder base directly under the Media Sensor and provides a positive reflective
surface to activate the printer.

Media Thickness Knob

The Media Thickness Knob is to the right of the STANDBY button on the side cover. It
adjusts for media thickness and is turned counter-clockwise for thin media, and
clockwise for thick media. The AstroJet Image Blaster may be adjusted for media up to
1-1/4” thick.

Bulk Ink Supply Tray

The AstroJet Image Blaster may be equipped with the HPC6119A Bulk Ink Supply
cartridges using the bulk ink supply tray. Refer to Section 3 – Installation and Setup for
information on how to install these and the regular ink cartridges.

Control Panel

The control panel is on the front of the unit and contains the controls and indicators
used to set up and operate the AstroJet Image Blaster

When you first turn on the AstroJet Image Blaster, you see the Image Blaster welcome
screen, and the STANDBY key is lit. The chart below describes the function of the
keys:

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CONTROL / INDICATOR DESCRIPTION

OPERATOR DISPLAY Indicates AstroJet Image Blaster status including

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

ON LINE When this indicator button is lit, the AstroJet

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

PREVIOUS When in menu mode, will scroll to the previous

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

NEXT When in menu mode, will scroll to the previous

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

SELECT Locks and unlocks selection when in the menu

mode.

TEST NOT FUNCTIONAL
RESET NOT FUNCTIONAL
STANDBY Toggles the printer between the ON LINE and

STANDBY modes.

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
Image Blaster in the MENU mode and permit access to the following settings and
adjustmen ts:

• Left Margin Setting

• Purge

• Counters

Interface and Power Panel

The interface and power panel can be found on the left side of the AstroJet Image
Blaster. It contains an outlet for an interface cable, Centronics parallel port, main power
switch, fuse, power cord receptacle, interface, encoder, and feeder connection.

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Encoder

The Encoder is mounted on the base unit and controls the printing of the information on
the media.

Refer to Section 3 – Installation and Setup for more information about the encoder and
its installation.

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Section 3 – Installation and Setup

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

• Choose a location for the AstroJet Image Blaster system

• Install the Image Blaster on the base unit

• Install the Encoder in the base unit

• Installing the inkjet cartridges

• Plug in the AstroJet Image Blaster

• Connect the AstroJet Image Blaster to the computer

• Install the AstroJet software

• Adjust for media thickness

• Position the printed output on the media

Choosing a Location

Ø The AstroJet Image Blaster Printer should be installed on the feeder base

and attached to your computer with a printer cable not more than 6 feet in
length.

Ø Use a grounded electrical outlet. DO NOT USE AN ADAPTER 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 Image Blaster from excessive heat, dust, and

moisture – avoid placing the system in direct sunlight.

Installing Image Blaster on Base

A template and two (2) 123-0182 1/4-20 bolts 3/4 inch long and two (2) 123-211 1/4-20
bolts 1-1/4 inch long, (2) 23-102-30 studs, and (2) 23-102-35 eccentric studs are packed
with the Image Blaster. The template pictured below is used to locate the position of the
four mounting holes of the Image Blaster on the base unit. This is done in the following
manner:

1. Disconnect the base unit from the power supply.

2. Locate the 23-100-35 template over an area of the base units’ transport belts.
The cutout in the template is the total available area that the print heads on
the Image Blaster can print in. Make sure that there are no rollers or other
obstructions in this area on the base.

3. With the front (thin end) of the template facing toward the front and
perpendicular to the direction of travel of the transport belts, mark the four
holes on the base. Use a square to make sure that the cutout in the template
is perpendicular to the transport belts.

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NOTE: The rear edge of the template has to be flush or hanging over the back
of the base unit. You cannot mount the Image Blaster forward of the rear of the
base due to its design, but you can have it hanging over the back of the base.

4. Clamp the template to the base and drill and tap four 1/4-20 holes in the base
top.

5. Fasten the Image Blaster to the base top on the right-hand side using the two
1/4-20 3/4inch long screws provided.

6. Install the 23-102-30 Studs using the 2 holes on the left-hand side of the
Image Blaster using the 1/4-20 X 1-1/4 inch screws provided.

NOTE: Two different style studs are provided in the kit. Use the studs that are
symmetrical. The second set of eccentric studs is only to be used if the holes are
not properly centered.

7. Lock the Image Blaster to the base locking the latches on the studs.

8. Install the Reflector Tape on the base unit directly below and centered on the
Media Sensor.

Installing the Encoder on Kirk - Rudy Base

Before operating the Image Blaster, the encoder that is supplied with it should be
installed on the conveyor tapes of the Kirk – Rudy Base.

1. Disconnect the base unit from the power supply.

2. Loosen the first transport belt guide on the conveyor unit directly under the
Image Blaster unit and slide it out of the way.

3. Remove the two clamp screws and attach the encoder over the shaft that the
belt guides are attached to.

4. Align the encoder assembly on the belt by lifting the spring-loaded roller.
Tighten the two clamp screws.

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5. Plug the encoder cable into the encoder connector on the Image Blaster.

Installing the Inkjet Cartridges

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

page 38.
HP 51645A Inkjet Cartridges

The AstroJet Image Blaster is configured with 6 inkjet cartridges standard or 8 as an
option. 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 latch mounted on the inkjet cartridge
holder. Release the latch 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 to secure
the cartridge in the
holder. Do not force
the latch into place.(See the diagram.)

• Repeat the above for the remaining cartridges.

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HP C6119A Ink System Cartridges

In addition to the standard Inkjet Cartridges, the AstroJet Image Blaster can be
equipped with the HP C6119A bulk ink supply. This system will print 10 times the
amount of media as the standard cartridge can print. A holder for these cartridges is
included with each AstroJet Image Blaster Printer. To use, simply attach the Bulk Ink
Cartridge holder on the rear of the printer cover with the screws supplied. To install the
cartridges follow the directions below:

• Remove the printhead from its packaging, and slide the reservoir out of the
left side of the system packaging. Do not throw the packaging away until the
system is installed in the printer. There are important directions on the
packaging for attaching the pen to the reservoir. Do not attempt to remove
the ink reservoir from it s diamond-shaped box. (See the caution labels on the
bottom panel of the ink reservoir. It is also important that the ink reservoir
does not get squeezed during the installation process. Squeezing the
reservoir could cause ink to seep out of the printhead.

• Place the reservoir in the tray that hangs from the back of the printer. There
are 4 notches in the tray. Each notch will accommodate two reservoirs. Do
not route the hoses at this time. Take care to not squeeze the reservoirs
when placing them in the tray.

• The system can be connected with the help of the directions located on the
printhead packaging. The valve should be inserted into the clip on the pen
until a clicking sound is heard or the operator feels the valve snap into place.
The valve and clip are symmetrical so there is no special orientation. Insert
the tubes into all of the printheads before the tape is removed from the
printheads. The tape will prevent the printhead from being damaged and will
help keep ink from leaking out of the printhead.

• Remove the tape from the printheads one at a time and insert them into a
holder beginning with the holder closest to the reservoir. It is important to
take the tape off of the printheads so that proper electrical connection is made
with the holder.

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• Install each printhead in turn taking care to route the hoses through the hose
guide and away from moving parts. Make sure that the hoses are not bent or
pinched as this would impede the flow of ink to the printheads

Once the connection is made between the printhead and the ink reservoir, it cannot be
taken apart without damaging the system. It is best if the system is left in the AstroJet
Image Blaster Printer, but sometimes that is not possible. When handling the system, it
is important to keep the pen as close to the reservoir as possible without letting it go
below the reservoir.

If the printhead is held more than 10 inches above the reservoir, air will be drawn into
the cartridge. Air inside of the pen can not only cause print defects, it can also cause
the pen to stop printing before all of the ink has been used. If the printhead goes below
the reservoir, ink will seep from the printhead, potentially damaging the system. Read
the Caution on the back of the reservoir.

The reservoir and prin thead should always be held together when handling the system.
The system should never be held or carried around such that the print head or reservoir
is dangling by the tubing. These actions could cause loss of ink.

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Plugging in the AstroJet Image Blaster

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

1. Connect one end of the power cord to the rear of the AstroJet Image Blaster
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 Image Blaster PRINTER TO THE WALL RECEPTACLE!

Connecting the Image Blaster to the Computer

In order for your computer and the AstroJet Image Blaster to work together, 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

Image Blaster to the computer must not exceed 6 feet long.

Installing the Software on the Computer

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.

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.

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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 bu tton. 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.

Adjusting the Image Blaster to the Media

Before operating the Image Blaster must be set to the proper height for the media being
printed.

1. Turn the media thickness knob on the Image Blaster clockwise until the media
can be positioned under the printheads of the Image Blaster.

2. Turn the knob counterclockwise until the guide rollers on the print carriage
assembly just touch the media.

3. Turn the base unit on and feed several pieces of media to check the
adjustment.

Positioning the Printed Output on the Media

Once the media thickness control is set you may position the printheads so that they
print in the proper place on the media. The printhead bands are held in place by a
thumbscrew in each cartridge holder. Loosen the appropriate screw and slide the
printhead to position it. Run a sample copy or the purge routine to determine the
position of the printheads.

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Notes

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Section 4 – Operating the AstroJet Image Blaster

Once the AstroJet Image Blaster is installed on the feeder base, the software has been
installed on the computer, and the printer has been supplied with ink cartridges, it is
ready to print. Using your existing database, you create a Layout template and Job file
with the AstroJet Layout Editor software. The computer sends the job to the printer
through the AstroJet Control Panel. The AstroJet Image Blaster then prints the Job with
both the addresses and other information you input in the layout.

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

• Software Tutorial

• Starting Up

• Preparing a Job

• Running a Job

• Printing Tips

AstroJet System 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 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.

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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