AstroJet 3600P? 3800P Operator's Manual

Astro Machine Corp.

630 Lively Blvd.

Elk Grove Village, IL 60007

Phone: [phone]

Fax: [phone]

www.astromachine.com

TM

AstroJet

3600P/3800P

PRINTER

OPERATOR MANUAL

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER,
CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE
ASTROJET 3600P/3800P PRINTER.

BEFORE USING THE PRINTER, 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, easily accessible wall

outlet located near the machine. Failure to properly ground the machine can result in severe personal injury
and/or fire.

 The power cord and wall plug is the primary means of disconnecting the machine from 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 trap it 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 equipment, walls or furniture.
 DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified

service representative. Report any cover damage 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 Astro Machine Corp., 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 Corp. nor any of its agents or employees shall
be responsible for any inaccuracies contained herein.

AstroJetTM is a registered trademark of Astro Machine Corp.
Hewlett-Packard is a registered trademark of Hewlett-Packard Corporation.
Windows 98, ME, 2000, NT and XP 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

Section 1 – Getting Acquainted

1

AstroJet 3600P/3800P
Control Panel
Optional Feeder Controls

1
2
3

Section 2 – Installing the Printer

5

Choosing a Location
Connecting the Printer and Optional Feeder
Installing the Optional Feeder
Installing the Inkjet Cartridges
Adjusting the Printer to the Media
Optional Feeder Setup
Installing the Printer Driver

5
5
6
7
8
8

10

Section 3 – Operating the AstroJet 3600P/3800P

11

Printer Operation
Printer Driver Properties
Printing from Microsoft Word

11
13
17

Section 4 – Maintenance

19

The Inkjet Cartridge
Jams in the Printer
Replacing the Sheet Separators
Cleaning

19
21
21
22

Section 5 –Troubleshooting

23

HP Inkjet Print Cartridges
The Printer

23
24

Appendices

25

Appendix A – Specifications
Appendix B – Supplies and Optional Hardware

25
26

Index

27

TABLE OF CONTENTS

Table of Contents

i

TABLE OF CONTENTS

Notes

ii

SECTION 1

1

MEDIA SIDE GUIDES – Guides the media to the Printheads.

2

MEDIA GUIDES – Holds down media to help guide it to the Printheads.

3

VACUUM TRANSPORT – The Vacuum Transport Belt helps transport the media to the Printheads.

4

MAIN POWER SWITCH AND RECEPTACLE – Printer receives power here. Also contains the Main

Power Switch and the Fuse Assembly.

5

USB PORT – Used to connect the Printer to some types of computers.

6

PRINTER/FEEDER INTERFACE CONNECTOR – Connects the Printer to the optional Feeder so

that they can function as a system.

7

PARALLEL PORT – Centronics Printer Port connects the Printer to the computer.

8

MOTOR CIRCUIT BREAKER – Protects the Motor in the case of a jam.

9

VACUUM TRANSPORT ON/OFF SWITCH – Controls the power to the Vacuum Transport Vacuum.

10

DOCKING STATION – Stores Ink Cartridges when not in use.

11

PRINTHEAD COVER – Protects the Printheads.

GETTING ACQUAINTED

Section 1 – Getting Acquainted

AstroJet 3600P/3800P

The AstroJet 3600 and AstroJet 3800 are 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 mail pieces. The 3600 has six Printheads and the
3800 has eight Printheads.

1

SECTION 1

1.

MEDIA THICKNESS – Knob on the right side of the Control Panel is used to
adjust the height of the Printheads to compensate for different media thickness.

2.

ON LINE key – Indicator lights when data is sent to the AstroJet 3600P/3800P

and printing is ready to begin. Also turns the Printer off line to access the Menu
Mode.

3.

FAULT Indicator – Lights when there is a problem with the printing process.

4.

- key – In Menu Mode, use to scroll to the previous selection.

5.

+ key – In Menu Mode, use to scroll to the next selection.

6.

ENTER key – Starts and stops printing.

7.

MENU key – Puts the Printer in the Menu Mode to access several operator
functions.

8.

OPERATOR DISPLAY – Indicates the Printer’s status including menus and
error messages.

9.

RESET key – Resets the Printer to its wait state.

10.

TEST PRINT key – Puts the Printer in the Test Mode and sends a sample copy

to check the Printer’s output.

GETTING ACQUAINTED

Control Panel

(AstroJet 3600P shown)

NOTE: A complete description of the functions and operation of the Printer Keys can be
found in Section 3 – Operating the AstroJet 3600P/3800P.

2

GETTING ACQUAINTED

1

SPEED – Used to vary the speed of the Feeder in either the MANUAL or AUTO

Mode to provide separation between the pieces.

2

CONTINUOUS – Pressing this switch with the Feed Select Switch in the

MANUAL position allows the Feeder tofeed continuously.

3

SINGLE – Pressing this switch with the Feed Select Switch in MANUAL Mode

allows the Feeder to feed a single piece of media.

4

BATCH COUNTER – Resettable to keep track of the pieces run on each job.

5

AUTO/MANUAL – With the Feed Select Switch in MANUAL, the operator can

feed one or continuous pieces of media by pressing the FEED switches. When in
AUTO, the Interface controls the Feeder through an external device.

1

POWER RECEPTACLE – Plug power cord here. Make sure that power cord is only

plugged into a properly grounded receptacle.

2

ON/OFF SWITCH – Controls power to the Feeder.

3

FUSE HOLDER – Fuse protects the electronics and motor in the Feeder.

4

INTERFACE CONNECTOR – Used to control the FF14 Feeder. (See Interfacing for

more information.)

OPTIONAL FF14 FRICTION FEEDER CONTROL PANEL

Control Panel

SECTION 1

Front Panel

3

SECTION 1
GETTING ACQUAINTED

Notes

4

SECTION 2

CAUTION

Do not use an adapter plug or extension
cord to connect the printer to the wall outlet.

Do not use outlets controlled by wall
switches.

Do not use an outlet that shares the same
circuit with large electrical machines or
appliances.

USB Port Parallel Port

INSTALLING THE PRINTER

Section 2 – Installing the AstroJet 3600P/3800P

To install the AstroJet 3600P/3800P Printer the following must be done:

 Choose a location for the AstroJet 3600P/3800P Printer and optional Feeder
 Place the Feeder and connect it to the Printer
 Plug in the Printer and Feeder, then connect the Printer to the computer
 Install the Inkjet Cartridges
 Set up the feed on the Feeder
 Install the AstroJet 3600P/3800P software on the computer
 Create a job to be printed (refer to Section 3 – Operating the AstroJet 3600P/3800P)

Choose a Location

Place the Printer with the Feeder on a sturdy worktable or cabinet at least 12 inches from any walls. Allow
enough room to place the Feeder on the same work surface. Protect the AstroJet 3600P/3800P from excessive
heat, dust, and moisture – avoid placing it in direct sunlight.

Place the Printer on the Support Stand if supplied. (The Stand is supplied only when the optional FF14 Friction
Feeder is used.)

Connecting the AstroJet 3600P/3800P and Optional Feeder

Plugging in the Printer

Make sure that the Printer's Main Power Switch is in the
OFF position.

1. Connect one end of the power cord to the rear of

the Printer in the corresponding receptacle.

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

Hz. grounded outlet.

Connecting to the Computer

Parallel Port: Plug the Parallel Printer Cable from

your computer into the rear of the Printer and latch the
two locking clips.
USB Port: You may also connect the Printer through
a USB connection if you are using Windows ME,
2000 or XP. NOTE: The Cable supplied with the

AstroJet 3600P/3800P should be used to connect
it to the computer.

5

SECTION 2

CAUTION

Do not use an adapter plug or extension cord to
connect the printer to the wall outlet.

Do not use outlets controlled by wall switches.

Do not use an outlet that shares the same circuit with
large electrical machines or appliances.

Printer Connection

Feeder Connection

INSTALLING THE PRINTER

Installing the Optional FF14 Friction Feeder

Assembling the Feeder

After unpacking the Feeder, install the two Side Guides as
shown using the four screws supplied (two on each side).

Place the Feeder on a flat level surface. The Feeder can be
permanently mounted by removing the four rubber feet,
aligning the Feeder on the Support Stand, then reinstalling
the feet to hold the Feeder in place.

Plugging in the Feeder

Make sure that the Main Power Switches on the Printer and the Feeder are in the OFF position.

1. Connect one end of the power cord to the rear of the Feeder in

the corresponding receptacle.

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

grounded outlet.

Connecting the Optional Feeder to the Printer

The Printer/Feeder Communication
Cable must be attached to the Printer and
the Feeder for the two machines to work
together. Remove the Jumper Plug from
the Printer (if installed) and attach the
Printer/Feeder Communication Cable
between the two machines as shown in
the photo at the right.

Completing Assembly of the System

Remove the packing blocks from the Printheads and install the Side Guides on the Feeder if not already done.

6

SECTION 2

The ink in the cartridge may be harmful if
swallowed. Keep new and used cartridges
out of reach of children. Discard empty
cartridges immediately.

INSTALLING THE PRINTER

Install the Inkjet Cartridges

Standard Cartridge Installation

The AstroJet 3600P can be configured with six Inkjet Cartridges and the AstroJet 3800P can be configured with
eight Inkjet Cartridges. Install standard Cartridges as follows:

1. 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.

2. The Cartridges are held in place by a Latch Lever mounted on the Inkjet

Cartridge Holder. Release the Lever by raising it vertically.

3. With the Cartridge’s Printhead pointing down, slide the Cartridge into the

Holder and push down and toward the contacts in the Holder.

4. 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 diagram.)

5. Repeat the above for the remaining Cartridges.

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

the Printhead" on page 39.

7

SECTION 2
INSTALLING THE PRINTER

Adjusting the Printer to the Media

Place one piece of media on the center of the
conveyor portion of the Feeder and adjust the Side
Guides [1] to the media. Use one or two Center
Straps [2] to help hold the media down. The Center
Belt has a vacuum-assist feature that can be turned
ON with the Vacuum Transport Switch located
above the Motor Circuit Breaker as required. It is
useful in feeding smaller size stock.

NOTE: The two narrow Belts can be moved
by turning the Printer ON and sliding the
Belt Guide Adjusters located under the
Conveyor Table in the appropriate direction
until they are under the media.

Optional Feeder Setup and Operation

1. Release the Separator Locking Lever and raise the

Separators to their up position as shown.

8

2. Place the media under the Separators and release

them so that they rest on the media. Then lock the
Separators in position using the Separator
Locking Lever.

3. Adjust the Side Guides to within 1/32" of the

media. Then adjust the Rear Guide so that the
media is raised approximately ½" (For heavy,
thick media this may not be required.)

4. Adjust the Exit Roller pressure by pushing in on

the Pressure Control Lock Button [A] and raising
or lowering the Adjusting Lever [B]. For plain
paper or envelopes the lever should be in the
down position, for thicker material the lever
should be adjusted so that the media is fed
without any bounce in the Exit Roller Assembly.

5. Turn on the Feeder and feed one piece with the

Speed Control set to low speed (1 or 2). Stop the
Feeder with the piece halfway through the exit.
Then adjust the Feed Sensor so that it is pointed
directly at the piece as it exits the Feeder. The
Sensor prevents double feeding in case of a jam or
stoppage.

SECTION 2

INSTALLING THE PRINTER

9

SECTION 2

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 5

1/8" to ¼"

5 to 7

¼"to 3/8"

7 to 10

INSTALLING THE PRINTER

6. Turn the Feeder Power Switch ON. Set the AUTO/MANUAL Switch to AUTO and press the

CONTINUOUS Feed Button for continuous feeding.

7. Turn the AstroJet 3600/3800 ON, then turn the Media Thickness Knob to set the initial Printhead height:

NOTE: These are initial settings. It may be

necessary to adjust the MEDIA
THICKNESS Control to optimize the
print quality.

8. To test-feed media after set up, turn the Feeder

and Printer ON. Place the AUTO/MANUAL
Selector Switch on the Feeder to the AUTO
position. Press the ON-LINE key on the Printer,
and then press the ENTER key, to test-feed media.

Installing the Printer Driver

A dedicated Printer Driver is included with the Printer. It must be installed on your computer before you install the
AstroPrint Software. Install the Driver for the Printer using the steps below.

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, then

click Next>.

4. Type in your Name and Company and click Next>.

5. Select the Printer Port LPT1 or

USB. Then click Next>. The
“Add Printer Wizard” will appear.
Select your printer from the list,
then click Next>

NOTE: The difference between
the L-R and R-L Printers is the
direction the media travels in.
L-R means Left to Right when
standing at the Printer’s
Control Panel.

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.

10

SECTION 3

OPERATING THE AstroJet 3600P/3800P P

Section 3 – Operating the AstroJet 3600P/3800P

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 AstroJet 3600P/3800P Driver.

This Section further assumes that you have connected the AstroJet 3600P/3800P to your computer.

Printer Operation

When you first turn the Printer ON, the ON LINE key light will blink. The Printer’s Display will show the message;
“Printer Off line / Enter for Paper Feed”. The TEST key light will be OFF. In this mode, pressing the ENTER key

starts the paper feeding, but no printing will take place.
To print you must put the Printer On-Line. When you do, the Display will change to the following message;

“Printer On line / Waiting for Data”. In this mode, when you send a job, the Printer will be ready to print when the
ENTER key is pressed.

The following is a description of the operation of the Printer’s various menu options that let you customize the
operation of the Printer to suit. 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:

TEST key

Pressing the TEST key momentarily places the Printer in the Test Print Mode. The word “Working” appears in the
lower half of the Display. 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.

NOTE: If you have chosen to have the Printer start automatically (see the Menu key below) the Printer will
start printing the Test Print once it is loaded without your having to press the ENTER key. In this case,
pressing the ENTER key will stop the paper feed.

To exit the Test Print Mode, press the TEST key again and the Printer will return to its ready state.
Pressing and holding the TEST key will cause the Printer to enter the “Service Menu”, where various functions of

the Printer can be tested. To exit the “Service Menu”, simply press the TEST key a second time. 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 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 and to customize the operation of 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:

NOTE: If the ON LINE key is ON, you cannot enter the Menu Mode. You must first take the machine off line
by pressing the ON LINE key.

Media Thickness Setup – The first item to appear in the Display is the “Media Thickness Setup”, if the Printer
is equipped with an Automatic Media Thickness Control. You can use this feature to pre-set the Printhead
height for various media thicknesses.

11

SECTION 3
OPERATING THE AstroJet 3600P/3800P P

Press Enter to Purge – The purging function is useful to clear the Printhead Nozzles when the machine has
been sitting idle for a time. To activate the Purge, press the ENTER key to feed one piece of media. To purge
the Printheads additional times, press the ENTER key for each additional purge.

NOTE: The Printer will only purge one piece each time you press the ENTER key. For additional
purges, press the ENTER key again for each subsequent purge.

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 the Printer OFF will not
reset this counter.

Purge First Piece – Turning the feature ON will cause the Printer to send one purge pattern on the first piece.
After the purge is completed, the next piece will be have the first record of your database. Once this is turned
ON it will remain ON even if the Printer is turned OFF.

Address Recovery – In event of a jam in the Printer, you can recover up to 10 pieces by pressing the MENU

key, then stepping to the “Address Recovery”. Then press the ENTER key. The message “Enter: Recover 1
Piece” will appear. Use the “+” key to select the number of pieces to reprint (1-10) then press ENTER again to

start the printing process. When the pieces are printed, press the ON LINE key and then the ENTER key to
resume printing the job.

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 Printhead Nozzles 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.

NOTE: The Print Enhancement feature will time out after 100 seconds if no media is going through the
Printer. Once media is being printed it will restart.

Automatic Feed – Turning the feature ON will cause the Printer to start feeding once the job is sent. If the ON
LINE key is ON the Printer will start feeding and printing automatically. If you prefer to press the ENTER

key to start the printing process, then turn this feature OFF. Turning the machine ON or OFF will not affect
your selection.

Pause Type: – This feature allows the Printer to respond to a “break mark” set in the database used in a given
job. The “break mark” marks the end of a series within the database. For example, addresses with the same
postal code or after a set number of entries. There are two “Pause Type:” selections:

Feed Stop – This setting is for standalone desktop units not used in line with other mailing equipment. The
Printer will stop feeding media for a set amount of time after it “sees” a “break mark”. Allows time for the
operator to pack or separate that set of printed pieces before the next set starts. Use the “+” or “-” key to
access this feature. Press ENTER to turn this function ON or OFF.

Conveyor Speed Up – This feature is for use when the Printer is used in line with other mailing equipment
(conveyors, tabbers, etc.) When this feature is activated, the Printer responds to the “break mark” by
sending a signal to the conveyor to speed up momentarily. This creates an obvious gap between the end of
one set of pieces and the beginning of the next. Use the “+” or “-” key to access this feature. Press ENTER
to turn this function ON or OFF.

Installing New Printheads – The Printer is capable of telling you when a Printhead is running low on 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.

12

SECTION 3

OPERATING THE AstroJet 3600P/3800P P

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 – Press the “+” key to display the version of the BIOS.
Bulk Ink – This feature is not used on the AstroJet desktop Printers. No provisions are made to install the

larger Cartridges.

+ / - key

Used to step through the options in various Menu Modes.

ON LINE key

If the ON LINE key is ON, the display shows the following message, “Printer On line / Waiting for Data” and the
light is ON. This means that the Printer is ready to print the job when it is sent. To have the Printer start printing
immediately when the job is sent you must also have the Automatic Feed feature turned ON. If the ON LINE key is
OFF the Display will return the following message, “Printer Off line / ENTER for Paper Feed”. In this condition the
machine can feed paper. This is useful for setting up the Feeder.

NOTE: If the Printer is off line and you send a job, the display shows “Printer Off line / Data Ready to Print”.
To print, you must first press the ON LINE key to put the Printer on line. If you sent data and the Printer is
set up not to start feeding automatically and the ON LINE key is lit, the display will show “Printer On line /
ENTER to Start Feed”.

ENTER key

Used to start the Printer printing when it is on line and the Automatic Feed is turned OFF. Additionally, when the
Printer is placed in any of the Menu Modes, the ENTER key is used to choose the options available.

RESET key

Used to clear the Printer Memory and return it to the wait state. This key only functions if the Printer is off line.

Purge While Printing

To do the purge in the middle of a job, follow these steps:

Press ON LINE to pause the current job.
Press MENU, then step to “Press Enter to Purge”.
Press ENTER to start the purge. Press ENTER again to stop purge.
Press ON LINE, then ENTER to get back to normal printing.

NOTE: If a paper jam occurs during the purge: after the purge you should use “Address Recovery” to
get back to normal printing. Otherwise you will lose records.

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. Through Properties you can control the output of the Printer.
The following describes the Properties Windows for the AstroJet 3600P/3800P and how to use them to customize
your Printer's output.

To start printing, click on File, then Print. The Print window opens. If
you wish to print the job, click OK. If you wish to use the Special
Features built into the AstroJet 3600P/3800P Drivers, click on the
Properties Button to open the Properties Window in Windows 98, NT,
or ME.

13

SECTION 3

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

OPERATING THE AstroJet 3600P/3800P P

If you are using Windows 2000 or XP the window at right will open. Clicking on
Advanced will open the “Options” window. In the following illustrations, the
windows for Windows 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 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. You can,
however change the speeds to a lower speed as follows:

14

SECTION 3

OPERATING THE AstroJet 3600P/3800P P

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 printed. 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”.

To use the Overlay feature: First create a layout in an application such as Microsoft Word. Place all of the fixed
information and graphics on this layout. Open the layout and go to Print in the File menu. Click on Features and
then click on Overlay. Select “Contains overlay” from the box, and then click on Apply and OK.

Next, click OK on the “Print” window. The Overlay will download and the Printer will start running.
Now open the job that contains the variable data and using File then Print from the dropdown menu open the

“Print” window for the application. Click on Properties then on the Features tab. Then click on the dropdown
menu under “Overlay” and click on Previous job contains overlay. Click Apply, then OK. When the Print window
reappears, click OK to send the job to the Printer. To start printing, press the ENTER key on the Printer.

If you wish to print a second job using the same Overlay, simply open that job and send it to the Printer. If the next
job does not contain an Overlay, then click on Properties in the “Print” window, select Overlay, then No overlay.
Click Apply, then OK.

To print the next job with a different Overlay, repeat the process for the first Overlay.

NOTE: Turning the Printer OFF, then ON will clear the Overlay and the job.

Print Heads Tab

The purpose of the Print Heads Tab is to permit slight (0.001-inch) adjustment to the position of the Printheads to
each other. The adjustment is used to precisely align the three Printheads when printing graphics or type that extends
beyond the width of one Printhead. Each head can be moved +/- 0.048-inch in 0.001-inch increments.

If you want to move the Printhead toward the lead edge of your layout, then it should be moved in the “-” direction.
To move the Head away from the lead edge, move it in the “+” direction.

15

SECTION 3
OPERATING THE AstroJet 3600P/3800P P

When the Printer is turned OFF, any changes made this way will return to their original settings.

Inverse Printing

The Paper Tab contains one element that is used to reverse or invert the printing on the AstroJet 3600P/3800P.
In normal operation, the printing is read from the operator side of the Printer. It is sometimes necessary to turn the

printing direction 180 degrees from the normal direction. This occurs when, due to the layout or the method of
binding, the media must be fed in the reverse direction.

Clicking on the Paper Tab, then on the Paper Source will permit you to reverse the printing direction 180 degrees.
The rest of the settings on this tab should be left as they are. Paper size is always “Max Print Area” and Orentation is

always “Portrait”. Do not change them.

16

SECTION 3

OPERATING THE AstroJet 3600P/3800P P

Printing from Microsoft Word

If you are not using a specific program designed for mailing applications it is possible to print your mail pieces
using Microsoft Word. This section will cover how to layout a piece and to print from Microsoft Word.

To begin, open a new page and turn on the Toolbar for “Mail
Merge”. Under Print, select the Address Printer 6 as the default
printer. Go to Page Setup in the File menu. Set all of the
margins to “0”.

NOTE: The Printer must be selected before you do the set
up so that the setting will be registered.

Next, select the Page Size tab and Custom Page. The size of the
layout should be 3-inches high by the length of the piece you
are intending to print. In our example, we have selected the
width of a # 10 envelope, 9.5-inches. The orientation of the
piece is always Portrait. The effective printing area of the
AstroJet 3600P/3800P is 3-inches by 15-inches. When you
have completed this step click OK.

The next step is to create a text box so that you can position the address the proper distance from the lead edge of the
piece. Once the page layout is set, you might want to save it as a template for use later.

When you have completed the steps above, the layout should look like the one below.

NOTE: When setting up a layout for the AstroJet 3600P/3800P, be aware that the Printheads are aligned in
two banks and these banks can be aligned so that you can print in a 3" or 4" wide spread over the width of
the media. Head 1 is on one rail and opposite it are Heads 5 and 6. There is a 1-3/4" gap between these Heads.
On the second rail, Heads 2, 3 and 4 are attached together. If you are using a 3800P, a second two heads, 7
and 8, are arranged opposite to these Heads. There is a 1-3/4" gap between Heads 2, 3 and 4 and Heads 7 and

17

SECTION 3
OPERATING THE AstroJet 3600P/3800P P

8. Head 1 can be combined with Heads 2, 3 and 4 to print 2" of information. In the 3800P, Heads 5 and 6 can
be combined with Heads 7 and 8 to print another 2" of information.

Click on Tools, then Mail Merge. The “Mail Merge
Helper” window will open. Click on Create, then
Envelopes. The “Microsoft Word” window will open.
Click on the Active Window button, and then click on
the Get Data button. Next, click on Open data source.
Locate the data file you intend to use. In our example,
we are using a Microsoft Excel file. Select the file and
the “Microsoft Excel” window opens. Select the entire
spreadsheet and click OK.

Next, click on Edit Main Document and then click on
Close.

Use the “Mail Merge” Toolbar, click on “Insert
Merge Field”, and begin to build the layout by
inserting the address fields.

When you have completed
setting up the layout, click on
the Mail Merge icon on the

toolbar and the “Merge”

window will open.
In the Merge to menu, there are

several choices for where and
how the data is exported. The
two that concern us are “New

Document” and “Printer”. If

you choose “New Document”,

the merge will be created in
your word application with a
separate record for each address. If you choose “Printer”, the merge will send directly to the Printer and each record
will be printed.

The next selection is “Records to be merged”. You can select All or From.
The last selection is “When merging records”. The default is “Don’t print blank lines when data fields are empty.”

This should be left checked.
Clicking on Merge will start merging the documents.
If you chose to send the merge directly to the Printer and the Printer is connected to the computer and turned ON,

the Printer will start. Pressing the ENTER key will start the printing process.
If you have a graphic or fixed text to be printed with the data, refer to the section on Overlays.

18

SECTION 4

600 x 600 DPI

50,000 addresses

300 x 600 DPI

100,000 addresses

200 x 600 DPI

150,000 addresses

150 x 600 DPI

200,000 addresses

CAUTION

NEVER SHAKE, DROP, OR HIT THE CARTRIDGE AGAINST THE PALM OF YOUR HAND
OR ANY OTHER HARD SURFACE. SHAKING THE PRINT CARTRIDGE DOES NOT “MIX”
THE INK AND HITTING THE CARTRIDGE AGAINST A HARD SURFACE DOES NOT
CLEAR THE NOZZLES. BOTH OF THESE ACTIONS ACTUALLY HURT THE PRINT
QUALITY BECAUSE THEY ALLOW BUBBLES TO FORM NEAR THE INK FIRING
CHAMBERS. THESE BUBBLES PREVENT THE NOZZLES FROM FIRING, CAUSING
WHITE STREAKS IN THE PRINT IMAGE.

MAINTENANCE

Section 4 - Maintenance

This section covers how to care for the Ink Cartridges, clear paper jams, replace the Sheet Separators, and perform
routine maintenance on the Printer.

The Inkjet Cartridge

The Inkjet Cartridges must be replaced when out of ink, when print quality is poor, or when purging and cleaning
have not helped the image quality.

The approximate life of the HP 45 Inkjet cartridges, based on three lines of 20 characters at 10-point size per
address, is:

NOTE: These figures can vary depending on the font selected.

To Replace the Inkjet Cartridge:

 Remove the used Cartridge from the Cartridge Holder by raising the Latch Lever to release the Cartridge,

and then pull the Cartridge up and out of the Holder.

 Remove the new 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 lever mounted on the Inkjet Cartridge Holder. Release the lever by

raising it vertically.

 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 lever to secure the Cartridge in the Holder.

Do not force the lever into place.

 Repeat the above for the remaining Cartridges.

19

SECTION 4

Cloth should be:

Cloth should not be:

 Soft
 Fiberless
 Moistened with water (Distilled is best but

tap water will work)

 Abrasive
 Made of small fibers
 Dry or contain chemical additives

MAINTENANCE

Storage

Short-term Storage – (less than 2 days or less than 1 day in a hot and dry environment.)

Store the Cartridge in the Docking Station.
The next time that the Printer is used, the Printhead may have to be cleaned and purged.

Long-term Storage – (more than 2 days or more than 1 day in a hot and dry environment.)

Place the Cartridges in the Docking Station, or
Place the Cartridges in a Tupperware® container with a damp sponge or towel to maintain humidity and

prevent the Printhead from drying out.
When the Cartridges are ready to be used again, the Printhead may need to be cleaned.

Disposal

The Cartridge may be disposed of in a normal manner.
In case of an ink spill, use soap and water to clean up any problem areas. Abrasive soap works well in getting ink

off of hands.

Cleaning the Printhead

To maintain good print quality it is important that the Printheads are kept clean. During the printing process ink
spray, paper fibers, and dust can cause a build-up on the Printheads. This build-up will eventually degrade the print
quality. If you begin to notice problems with the quality of the print, or to just prevent a build-up from occurring,
wipe the Printhead with a wet fiberless cloth.

Wipe slowly across the long-axis with the Printhead
facing down (as shown). Do not apply excessive force,
as this could scratch the Nozzle area.

20

SECTION 4

MAINTENANCE

Purging the Nozzles

If the Printhead sits inactive for a time, ink may dry in the Nozzles. Printing may not remove these “ink plugs” from
the Nozzles. White streaks will then show up in the printed text or graphic. In order to obtain better print quality,
these ink plugs need to be forced out or purged. A Purge routine is built into the AstroJet 3600P/3800P Printer. It
can be accessed from the LCD Panel on the Printer from the MENU key. If this does not solve the problem, then
proceed as follows:

1. Wipe the Printhead with a wet cloth as described in “Cleaning the Printhead” above.

2. Perform the Purge routine from the Printer by pressing the MENU key momentarily and then the “+” key. Load

media and press the ENTER key to purge. Repeat if necessary.

3. Wipe the Printhead again with a moist cloth.

NOTE: For more information, refer to Troubleshooting Printheads in Section 5 – Troubleshooting Guide.

Jams in the AstroJet 3600P/3800P Printer

If a jam occurs, STOP the Printer. Up to 10 missed addresses can be recovered at the Printer Control Panel. (See
Section 3 – Operating the AstroJet 3600P/3800P “Print Recovery After Jam”.)

Some possible reasons for jamming are:

1. Feeding more than one piece of media.

2. Damaged media, such as dog-eared (turned down corners).

3. Media that is not stiff enough may not be usable. Media that meets Postal stiffness requirements for automated

feeding is acceptable in the AstroJet 3600P/3800P.

4. Envelopes that are caught under the flap of another envelope or stuck to one another may cause jamming.

Removing Jammed Media

1. It may be necessary to move one or more of the Printheads to gain access to the jammed media. Take care in

removing jammed media to prevent damage to the Printheads. All pieces of the jammed media must be removed
from the feed path.

2. Follow the instructions in Section 3 – Operating the AstroJet 3600P/3800P “Print Recovery After Jam”.

Replacing the Sheet Separators on Optional Feeder

The Sheet Separators insure separation of the pieces as they are being fed. They do wear and must be replaced from
time to time. If you experience double sheet feeding and cannot adjust the Separators to prevent it, they should be
replaced. Replacement of the Sheet Separators is not difficult, simply follow the steps below:

1. Turn off the Feeder and unplug it from the power source.

2. Release the Separator Locking Lever and move the Paper

Side Guides to their maximum open position.

3. Lower the Separators so that they touch the Feed Roller.

4. Remove the screw [A] and the Separator Support [B]. Then

remove the Separator [C] by prying it out of the Holder.

5. Install a new Separator in place and replace the Separator

Support and screw.

21

SECTION 4

WARNING

THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED

REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING

ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE!

CAUTION

NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE
PRINTER. EXCESS LIQUID COULD HARM ELECTRONIC PARTS.
ALWAYS DAMPEN A RAG WITH THE CLEANER AND APPLY IT TO THE
PARTS TO BE CLEANED.

MAINTENANCE

Cleaning

The Printer must be cleaned regularly of accumulated paper dust and ink. Depending on the types of media that are
run, paper dust may accumulate within the Printer and on the Transport. To properly clean the Printer, unplug it
from the power receptacle and remove the covers.

 Internal Areas: Best cleaned with a vacuum that has a soft brush attachment to help loosen the dust

particles. Take care not to damage the PC Boards or electrical wiring.

 Exterior Areas: May be cleaned with any standard non-abrasive household cleaner that does not contain

plastic-harming solvents.

Feed Rollers and Forwarding Rollers on Optional Printer

The Feed and Forwarding Rollers can become glazed with paper lint and ink from the media. They should be
regularly cleaned with a mild abrasive household cleaner on a damp cloth.

Avoid using solvents on the Rubber Rollers.

Cleaning the Media Sensor

Periodically check the Media Sensor located in the Print Carriage area of the Printer section. The Sensor should be
clean and free of accumulated paper dust. Use a vacuum with a soft brush attachment or dry compressed air to
remove the dust.

22

SECTION 5

CONDITION

PROBLEM

SOLUTION

Black streaks in text

Lint or paper dust on Printhead.

Clean the Cartridge Nozzles
with a clean lint-free cloth
moistened with distilled water.

Cartridge will not print

Sheet is blank even after it has
gone underneath Cartridge(s).

Check to make sure the tape is
off the Printhead.
Remove and reinsert the
Cartridge into the Carriage
Holder.
Install a new Print Cartridge.

White streaks in text or
graphics

Lint or dust blocking Printhead
holes.
Poor contact between Printhead
and Printhead Holder.

Clean the Cartridge Nozzles
with a clean lint-free cloth
moistened with distilled water.
Clean Interconnects.
Remove and reinsert the
Cartridge into the Holder.
Insert a new Print Cartridge.

TROUBLESHOOTING

Section 5 – Troubleshooting Guide

The following Troubleshooting Guides are provided to assist you in solving any problems that might occur with the
AstroJet 3600P/3800P Printer or its software. We have tried to make them as complete as possible. The best advice
we can offer is to make sure that the system is setup properly, plugged in, that it has an adequate supply of ink
before attempting to troubleshoot any problem.

HP Inkjet Print Cartridges

23

SECTION 5

CONDITION

PROBLEM

SOLUTION

Extra lines; losing data

Database problem

Check data in database program

Improper output (address
information out of order, miss­feeding, etc.)

Wrong Interface settings
Static electricity

Dirty Media Sensor

Check software or database on
PC.
Close AstroJet Control Panel
software, the turn Printer OFF and
ON.
Clean Media Sensor.

Media jams

Double feeding
Media is curled or bent
Media is too thin

Adjust Sheet Separators on
Feeder.
Uncurl media.
Media must be at least 0.008".

No communication

Improper cabling / connector
Unit not receiving power

Use proper cable (see Operator
Manual).
Check plug connections, ON/OFF
Switch and Fuse on Back Panel
(see Operator Manual).

Not printing on media

Media not positioned properly

Adjust Printhead vertically.
Adjust margin setting in layout
software.

Print too light or missing
character dots

Clogged or dirty Printheads
Running out of ink

Purge or clean Cartridges.
Replace Inkjet Cartridges.

Blurry address

Image is not sharp

Printhead gap too high. Adjust
Printhead closer to the media.

Split line of type

Line of type is placed across two
Printheads

Reposition the text in the layout
so that it does not print across two
Printheads.
Adjust the positioning of the two
Printheads in relationship to each
other using the Head Alignment
in the Properties window of the
PCL Driver.

Uneven split line of type

Some but not all of a line of type
across two Printheads matches
up

Reposition the text in the layout
so that it does not print across two
Printheads.
Check the Sheet Separator
adjustment. Separators should just
touch the media.
Check that the Printhead is set at
the proper height. A Printhead
that is too high will cause slippage
in the media as it is passing under
the Heads.

WARNING

DO NOT REMOVE THE SIDE COVERS OF THE PRINTER!

THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!

TROUBLESHOOTING

The Printer

24

APPENDIX A

PRINT TECHNOLOGY

Inkjet, 6 or 8 HP 45 High Capacity Inkjet Cartridges

ADDRESS SPEED

Up to 26,000/hr - #10 Envelopes

PRINT QUALITY

(Dots Per Inch)

High Quality 600 x 600 dpi
Standard Quality 600 x 300 dpi
Letter Quality 600 x 200 dpi
Draft Quality 600 x 150 dpi

IMAGE AREA

3" or 4" x 17"

PRINT ORENTATION

Normal and Reverse

INK MONITOR

Visible on Display

FONTS

All TrueType fonts available on PC

PRINTS

Prints graphics, logos, and barcodes

MATERIAL SIZE

Length – 5" to 17"
Width – 3" to 13.5"

MATERIAL THICKNESS

Up to 3/8"

MEMORY

12 MB

PRINT COLORS

Versatile Black and General Black, Red, Blue, Green, and Yellow

INK

Water-based, may require drying assistance for coated stock

SOFTWARE

WindowsTM Printer Drivers for WindowsTM 98, 2000, NT, ME, and XP

DIAGNOSTICS

Resident in firmware

FIRMWARE UPDATE

Flash PROM update.

PC INTERFACE

Centronics Parallel

COUNTERS

One operator resettable job counter, one permanent lifetime counter

DUTY CYCLE

75 million addresses total or
1,250,000 per month over a 5-year life cycle.

DIMENSIONS

11.5" H x 30" L x 23" W (29.2 cm H x 76.2 cm L x 58.4 cm W)

WEIGHT

90 lbs. (40.9 kg)

ELECTRICAL

AstroJet 3600P/3800P 115VAC or
AstroJet 3600P/3800PE 240VAC, 50/60 Hz

OPTIONS

Left-to-Right or Right-to-Left Operation, Stand, Conveyor/Stacker and
Feeders

Appendix A – AstroJet 3600P/3800P Specifications

All Specifications Subject To Change Without Notice

25

Red Inkjet Cartridge

HPC6168A

Green Inkjet Cartridge

HPC6169A

Blue Inkjet Cartridge

HPC6170A

Yellow Inkjet Cartridge

HPC6173A

Versatile Black

HPC8842A

General Black (works on high gloss
media when used with dryer)

IQ2392
Vacuum Feeder

Friction Feeder

Conveyor / Stacker Available

Stand

APPENDIX B

Appendix B – Supplies and Optional Hardware

The following supply items and optional hardware are available from your
Astro Machine Dealer:

Supplies

Optional Hardware

26

- key

2, 13

+ key

2, 13

A

Address Recovery

12

Adjusting Side Guides

9

Adjusting Transport Belts

8

Advanced Properties

14

Aligning Printheads

15

Automatic Feed

12

B

BIOS Version

13

Blurred Printing

24

Broken Lines

24

Broken Printing

23

Bulk Ink

13

C

Cartridge Disposal

20

Cartridge Installation

7

Cartridge Replacement

19

Cartridge Storage

20

Choose Location

5

Choosing Printer

10

Circuit Breaker

1

Cleaning Feed Rollers

22

Cleaning Machine

22

Cleaning Printhead

20

Clear Batch Counter

12

Connection, Computer

5

Connection, Feeder

6

Connection, Printer

5

Connector, Interface

1, 3

Control Panel, Friction Feeder

3

Control Panel, Printer

2

Conveyor Speed Up

12

D

Display, Feeder

3

Display, Printer

2

Docking Station

1, 20

Driver Features

13

Driver Properties

13

E

Enter Key

2, 11

F

Fault Indicator

2

Features Tab

14

Feed Delay

15

Feed Roller Cleaning

22

Feed Stop

12

Feeder Assembly

6

Feeder Auto/Manual

3

Feeder Batch Counter

3

Feeder Connection

6

Feeder Continuous

3

Feeder Interface

1, 3

Feeder On/Off

3

Feeder Power

3

Feeder Setup

8

Feeder Single

3

Feeder Speed

3

Fuse, Feeder

3

I

Inkjet Cartridge

7, 12, 19

Installing Computer

5

Installing Feeder

6

Installing Inkjet Cartridges

7

Installing New Cartridges

12, 19

Installing New Printheads

19

Installing Printer Driver

10

Inverse Printing

16

J

Jam in Printer

21

Jam Recovery

12

Jam Removal

21

Jams

21, 24

L

Left-to-Right

10

Locating System

5

Long Term Storage

20

M

Main Power Switch

1, 3

Maintenance

19

Media Guides

1

Media Sensor Cleaning

22

Media Thickness

2, 10

Menu Key

2, 11

Microsoft Word

17

Missing Records

24

Motor Circuit Breaker

1

N

No Print

24

INDEX

27

O

On Line Key

2, 13

Operator Display

2, 3

Optional Hardware

26

Overlay

15

P

Parallel Port

1, 5

Pause Type

12

Power Receptacle

1,3

Print Enhancement

12

Print Heads Tab

15

Printer Cleaning

22

Printer Display

2

Printer Driver Install

10

Printer Driver Properties

13

Printer / Feeder Interface

1, 3

Printer Operation

11

Printer Speed

14

Printer Troubleshooting

24

Printhead Alignment

15

Printhead Cleaning

20

Printhead Cover

1

Printhead Purging

21

Printing Blurry

24

Printing from Microsoft Word

17

Printing Inverse

16

Printing Light

24

Printing Troubleshooting

23

Purge

12

Purge While Printing

13

Purging Printheads

21

R

Records Missing

24

Recovering from Jam

12, 21

Replacing Cartridges

19

Replacing Sheet Separators

21

Reset Key

2, 13

Resolution

14

Right-to-Left

10

Rollers, Cleaning

22

S

Sheet Separator Replacement

21

Short Term Storage

20

Side Guides

1

Smeared Printing

23

Specifications

25

Speed, Printer

14

Storing Cartridges

20

Streaked Printing

23

Supplies

25

T

Test Print key

2, 11

Total Count

13

Transport Belt Adjustment

8

Troubleshooting Printer

24

Troubleshooting Printheads

23

Troubleshooting Printing

23

U

USB Port

1, 5

V

Vacuum Transport

1

Vacuum Transport Switch

1, 8

INDEX

28

Copyright © 2013 ASTRO MACHINE CORP.

Elk Grove Village, IL 60007

09/05/2013

Part Number: 200-AJ3600/3800PCL Rev I