Rena AS-150 Service Manual

AS-150 PRINTER

SERVICE MANUAL

Rev 10-14-15

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
OBSERVE SAFETY RULES WHEN OPERATING THE AS-150 PRINTER.

BEFORE USING PRINTER, READ THIS MANUAL CAREFULLY AND FOLLOW
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 machine is in use. Before clearing a jam, be sure

machine mechanisms come to a stop.

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

maintenance covered in this manual.

 Use power cord supplied with machine. Plug it into a properly grounded, easily accessible wall

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

 Power cord and wall plug are primary means of disconnecting machine from power supply.
 DO NOT use an adapter plug on line cord or wall outlet.
 DO NOT remove ground pin from line cord.
 DO NOT route 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 power cord caused by jamming it 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 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 Neopost USA, its designated agents, 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 Neopost USA nor any of its agents or employees shall be responsible for any inaccuracies
contained herein.

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

Table of Contents

SECTION 1 – Installation 2

Contents of Packaging 2
Assembling Printer 2
Install Rear Media Support 3
Install Rear Media Guide 3
Connecting Printer 4
Install Inkjet Cartridges 5
Set up Feed 6
Install Printer Driver 7
BIOS Manager 8

SECTION 2 – Troubleshooting 9

Service Diagnostic Tests 16
Sensor Test 16

SECTION 3 – Functional Operation 17

Sequence of Operation 17
Printer Control Panel 18
Printer Control Panel 19
Purge While Printing 21
Printer Driver Properties 22
PC Board and Electrical Component Location 25

SECTION 4 – Adjustments 26

Drive Belt Tension Adjustment 26
Encoder Belt Tension Adjustment 27
Output Voltage Adjustment 28
Media Sensor Adjustment 29
LCD Display Adjustment 30
Brake Adjustment 31

SECTION 5 – Disassembly/Assembly Procedures 32

Tools Required 32
Basic Disassembly 32
Replacing Separator Tips 34
Service Disassembly Procedures 35

SECTION 6 – Maintenance 47

Inkjet Cartridge 47
Jams in Printer 49
Replacing Sheet Separators 49
Cleaning 50

APPENDIX A – Printer Specifications 51
APPENDIX B – Supplies 52
INDEX 53

i

SECTION 2

1.

AS-150 Printer

2.

Power Cord

3.

Software

4.

Side Guides

5.

Rear Media Support & Guide

6.

Operator Manual

INSTALLING PRINTER

SECTION 1 – Installation

Contents of Packaging

Assembling Printer

Tools required: Standard #2 Phillips head screwdriver.

Install Side Guides

1. Remove two screws from Side Guide Blocks.

2. Position Side Guide screw holes so they

align with holes in Side Guide Blocks.

3. Insert screws removed in Step 1 and

tighten so Guides are firmly attached to
Side Guide Blocks.

2

Install Rear Media Support

1. Install Rear Media Support using two

screws [A] (included) onto Rear Center
Plate (as shown).

Install Rear Media Guide

SECTION 2

INSTALLING PRINTER

1. Insert Adjusting Knob [A] through Rear

Media Guide and Rear Media Support.
Screw into rectangular washer [B].

3

SECTION 2

CAUTION

DO NOT USE ADAPTER PLUGS OR
EXTENSION CORDS TO CONNECT
PRINTER TO WALL OUTLET.

DO NOT USE WITH OUTLETS
CONTROLLED BY WALL SWITCHES.

DO NOT USE WITH OUTLETS THAT
SHARE SAME CIRCUIT WITH LARGE
ELECTRICAL MACHINES
OR APPLIANCES.

INSTALLING PRINTER

Connecting Printer

Plugging in Printer

Make sure Printer’s Main Power Switch is turned OFF.

1. Connect one end of power cord to rear

receptacle on Printer.

2. Plug other end into a 115-220 Volt AC,

50/60 Hz. grounded outlet.

Connecting to Computer

USB Port: Plug USB cable into USB connector.
Cable used to connect Printer to computer must
not exceed 6 feet long.

4

Ink in Cartridge may be
harmful if swallowed.
Keep new and used
Cartridges out of reach of
children. Discard empty
Cartridges immediately.

Install Inkjet Cartridges

Printer has 3 Inkjet Cartridges. To install Cartridges:

1. Remove Inkjet Cartridge from packaging.

Take care not to touch copper contacts,
metal plate, or gold printhead. Remove
protective tape from Printhead.

2. Open Latch Lever mounted on Inkjet

Cartridge Holder.

3. With Cartridge’s Printhead pointing

down, slide Cartridge into Holder. Push
down and toward contacts in Holder.

4. Make sure Cartridge is seated in Holder.

Close Latch Lever to secure Cartridge.
DO NOT force Latch Lever into place.

5. Repeat Steps 1-4 for remaining

Inkjet Cartridges.

SECTION 2

INSTALLING PRINTER

5

SECTION 2
INSTALLING PRINTER

Set up Feed

Printer has two Sheet Separators, two Side Guides, and a Rear Media Support and Guide.
Adjust Sheet Separators individually as follows:

1. Move Side Guides to access locking screws.

2. Loosen locking screw(s) [A] (as shown) and

raise Separator.
Tighten locking screw to hold Separator in
raised position.

3. Place media under Separators. It is best to

place media in center position on Table.

4. Loosen Separator locking screw.

Place Separator on media and tighten
locking screw.
Repeat for remaining Separator.

5. Adjust Side Guides so they are about 1/32"

from sides of media. Tighten locking screws on
Side Guides.

Set Side Guides to direct media so Printheads
print on desired print area of media (top edge,
middle, bottom edge).

6. Adjust Rear Guide by loosening locking screw

[B]. Slide Guide so media is raised
approximately 1/2" above Rear Media
Support. Tighten locking screw.

7. Test feed media by pressing ON LINE key,

then ENTER key. Press ENTER to stop
feeding, then press ON LINE to stop Printer.

6

INSTALLING PRINTER

Install Printer Driver

Install Printer Driver (CD included) on your computer.

NOTE: Driver for Printer should start when installed. If it does not, use steps below.

1. Close any applications running on your computer.

Restart computer before installing Driver.

2. Install CD in CD drive: Click “Open folder to view

files”. Then select and double-click “Setup.exe”.

3. “Add, Update or Delete Printer” window opens.

Click “Add New Printer”. Click Next>.

4. “Install Printer Driver”

window opens. Select
manufacturer and model of
your printer. Click Next>.

5. Select USB Printer Port.

Click Next>.

6. Next screen allows you to

“Name Your Printer”.
Unless another printer has the
same name on your system or
network, ignore this step and
click Next>.

SECTION 2

7. Click Finish to complete

the installation.

8. Check in “Devices and

Printers” that Printer is
available and active.

7

SECTION 2

WARNING!

DO NOT TURN OFF OR DISCONNECT PRINTER DURING DOWNLOAD
PROCESS. DOING SO WILL DAMAGE MAIN PROCESSOR PC BOARD.

INSTALLING PRINTER

BIOS Manager

BIOS Manager is used to upgrade the BIOS in the Printer. Occasionally you may receive a new BIOS for
the Printer. It must be loaded in the Printer's flash ROM. This is where the BIOS Manager comes in. After
receiving new BIOS either via e-mail or on a disk, it has to be loaded into the BIOS Manager software.

1. Make sure that the Printer is connected to the computer via USB cable and turned ON.

2. Open the Printer CD. Find and

click “FirmwareMgr.exe” to start
the program.

3. BIOS Manager window opens.

Click “Browse” to find the new
firmware. Select the new BIOS file
from the list of BIOS.
Click on the selection.

4. BIOS Manager window opens

again. Click “Download”.

5. This returns you to the BIOS

Manager window. Check that the
“Flashing:” line is turning green
Program installs new the BIOS
firmware on the Printer. Check that
the Printer Display shows:

“A firmware update is in
progress…”

6. Download is complete when the Printer restarts itself or when you see that the “Download” button is

active again. Click “Close”.

8

SECTION 2

CONDITION

PROBLEM

SOLUTION

Power is ON,
nothing happens

No power to Printer

Check that power cord is plugged in.
Check that power outlet is live.
Check fuse in Main Power Switch.

Replace with fuse of same rating.
Bad Controller PC Board. Replace.
Bad Power Supply. Replace.

CONDITION

PROBLEM

SOLUTION

Printer does not respond
to software

Connection problems

Check that port is communicating
with Printer via USB cable. If not,
replace cable.

If port cannot communicate using
another USB cable, check Printer.

If port cannot communicate using
USB cable and Printer is OK, check
USB port.

Check USB cable for breaks/damage.
If so, replace cable.

Poor connection between
Printer and computer

Turn Printer OFF and ON again.
Check connections.

TROUBLESHOOTING

SECTION 2 – Troubleshooting

This section is arranged by first the condition that might occur, and then by possible problems, their cause
and recommended solutions.

Power Problems

Interface Communication Problems

9

SECTION 2

CONDITION

PROBLEM

SOLUTION

No LCD display

Power not ON

Contrast Pot broken or maladjusted

Broken solder joint on Contrast Pot

Turn power switch ON. If still no
display, see Power Problems.

Adjust Pot or replace Display
PC Board.
(see Section 4-Adjustments)

Repair or replace Display
PC Board.

LCD shows solid line or
garbled characters

Power Supply

Static electricity

Check voltages and inspect Power
Supply connections to processor
PC Board.

Turn Printer OFF, then ON.

LCD displays solid
black line or lines

Bad Power Supply
No firmware (BIOS)
Bad processor PC Board

Check all voltages.
Install firmware.
Replace processor PC Board.

CONDITION

PROBLEM

SOLUTION

Intermittent feeding

Feed Ramp not used

Side Guides set improperly
Dirty Feed Rollers

Paper stuck together

Bad or dirty Sensor

Uneven mail piece

Feed Ramp adds a slope to media
stack and helps feeding.

Loosen Side Guides slightly.
Clean Feed Roller with distilled

water and a cloth. DO NOT use any
solvents or detergents as they may
damage Feed Rollers.

Fan media before placing it
in Printer.

Clean Sensor with compressed air
or replace it.

Tap inserts to front of envelopes
and retry.

Multiple feeds

Separator gap not set properly

Sensor bad or dirty

Media stuck together
Side Guides too close to media
Brake misadjusted

Adjust Sheet Separators to
media thickness.

Clean Sensor with compressed air
or replace it.

Fan media before feeding.
Push Side Guides away from media.
Adjust Brake

(see Section 4-Adjustments)

TROUBLESHOOTING

LCD Display Problems

Feeding Problems

10

CONDITION

PROBLEM

SOLUTION

Failure to feed

Side Guides too close to media
ENTER key not pressed
No power to Printer

Feed gap too tight
Feed gap too loose
Material is out of specification.
Motor ON, Feed Rollers

not turning

Clutch not engaging
Motor failure
No power

Readjust Side Guides.
Instruct user on proper operation.
Check power button is ON and

power cord is plugged in.
Adjust Separator to media thickness.
Adjust Separator to media thickness.
Maximum thickness: 0.020"
Press ENTER key, check for broken

Drive Belt and replace, check for
loose set screws on Drive Pulley or
Belt Drive Roller Pulley.

Replace Clutch.
Check or replace Motor.
See Power Problems in this Section.

Jams

Paper path obstruction

Paper not loaded properly

Feed Ramp not used properly
Separators improperly adjusted

Media curled or bent
Bad or dirty Sensor

Clear jam and remove pieces
remaining under Printhead.

Instruct operator in proper loading
of media.

Set Feed Ramp.
Adjust Separators to thickness

of media.
Uncurl media.
Clean or replace Sensor.

Worn Separator Tip
Conveyor tape (Transport Belt)

under Printhead broken

Replace Separator Tip.
Replace tape (Transport Belt).

Feeding Problems (continued)

SECTION 2

TROUBLESHOOTING

11

SECTION 2

CONDITION

PROBLEM

SOLUTION

No printing: Media is blank
after going under Printheads

Sensor did not see the piece or
send signal to print to PC Board

Clogged Cartridges
Cartridge dried out
Tape on Printhead
Cartridge not properly inserted
Cartridge empty
Power Supply voltage out of spec
Printhead Holder

Clean or replace Sensor.

Clean and purge Cartridges.
Install new Cartridge.
Remove tape.
Remove and reinsert Cartridge.
Install new Ink Cartridge.
Check voltages.
Check Flex Circuit for tears.

Print slanted or skewed

Skew within specs.

Side Guides not set properly

± 2.5° from bottom edge
of material.

Readjust Side Guides.

Gray print

Ink cartridge almost dry

Replace Ink Cartridge.

Blurry print

Dirty Printheads
Paper too porous or absorbent
Printheads scratched

when cleaned

Clean Printheads.
Use other paper.
Replace Printhead.

Printing light

Printhead clogged or dirty
Resolution of output set too low
Running low on ink

Purge and clean Printheads.
Reset to a higher resolution.
Replace Cartridge.

Print streaking

Exit Roller dirty
Printhead dirty

Clean Exit Roller with water.
Clean Printhead.

TROUBLESHOOTING

Printing Problems

12

CONDITION

PROBLEM

SOLUTION

Non-uniform print quality

Check voltage from power supply

Poor Printhead connections

Adjust to 14 VDC. (See “Output
Voltage Adjustment”)

Check that Flex Circuit
connections are in place.

White lines/streaks in a
line of print

Ink Cartridge Nozzle dirty
Cartridge not properly inserted
Cartridge was hit, shaken,

or dropped
Tap water was used to clean

Cartridge and mineral deposits
have blocked the Ink Chamber

Wiping wrong way or too hard
drove particles into Nozzles

Cartridge low on ink
Tape covering Print Nozzle or

Vent Holes
Printhead connections not set

Bad Printhead Drive Card

Clean Cartridge.
Remove and reinsert Cartridge.
Replace Cartridge.

Replace Cartridge.

Replace Cartridge.
Instruct operator in proper
cleaning method.
(See “Cleaning Printhead”)

Replace Cartridge.
Remove tape.

Check that Flex Circuit
connections are in place.

Replace Printhead Drive Card.

Smeared ink

Coated paper preventing ink
absorption

High humidity slowing
drying time

Use fast-dry ink and/or allow
more time to dry after printing.

Use fast-dry ink and/or lower
dpi resolution.

Printing Problems (continued)

SECTION 2

TROUBLESHOOTING

13

SECTION 2

CONDITION

PROBLEM

SOLUTION

Print too close to leading
or trailing edge of media

Size of media not set correctly
in Layout

Bad or dirty Sensor
Feed Ramp not used properly

Check layout in Layout for
proper size.

Clean or replace Sensor.
Set Feed Ramp.
Check location and margins in

layout software. Check that piece
on layout screen looks exactly the
way you want the piece to look.

Print too high or low
on the media

Physical location of Printhead
does not match layout template

Adjust Media Guides.
Use “0” reference point in center

of scale to help you align print
on media.

Address prints upside
down on media

Layout and/or media
direction incorrect

Change direction from Normal to

Inverted or Inverted to Normal in
Driver Properties.

Address too close to center
of media

Chosen media size in layout is
too small

Physical location of Printheads
do not match layout

Feed Ramp not set properly

Set correct media width size
in Layout.

Check image on layout screen,
adjust Media Guide or media.

Adjust Feed Ramp.

Address printing partially
off media

Chosen media size in layout is
too large

Physical location of Printheads
do not match layout

Feed Ramp not set properly

Set correct size in Layout.

Check image on layout screen,
adjust Media Guide or media.

Adjust Feed Ramp.

TROUBLESHOOTING

Print Placement Problems

14

CONDITION

PROBLEM

SOLUTION

Information being printed
is wrong, incomplete,
or garbled

Poor cable connections

Interface problem
Corrupted database file

Check USB cable:

Securely fastened at both ends.
Cable length not more than 6-ft.
Printer's internal USB cable in

good condition.
Check Printer setup at computer.
Use another database file.

Barcode does not print

Wrong font selected

No zip code in database

Barcode not enabled

If using a combined field
barcode, choose USPS
barcode font.

Put zip code field in database or
use another database.

Enable barcode.

Unwanted BOLD, Italic, or
Underlined type

Turned on in layout

Open layout and change
type style.

Not all addresses in
database print

Only some addresses in database
were selected to print

Start new job and select
entire database.

Data being lost

Database problem
USB cable connection loose

Check database program.
Check/reconnect cable.

Graphics or text have a
white line through them

Graphic or text is set between
junction of two Printheads.

Move copy or adjust media.

Print Content Incorrect

SECTION 2

TROUBLESHOOTING

Software Problems

Refer to the manual for the application software being used.

15

SECTION 2
TROUBLESHOOTING

Service Diagnostic Tests

TEST PRINT key

Press TEST PRINT to place Printer into Test Print mode. Press ENTER to print a test sheet.
NOTE: Remove all media from Printer before performing these tests.

To access Test Print mode, press and hold TEST PRINT until “Service Menu” is displayed on Printer
Control Panel. Use “+” or “–” keys to step through test options.

Drive Speed Test

Press ENTER to start Main Drive Motor and display Belt Speed in inches per second. Press ENTER again
to stop Main Drive Motor. If Main Drive Motor does not start, Main Drive Motor circuitry has a problem.
No reading in inches per second indicates an Encoder problem.

Motor Test

Press ENTER to start Main Drive Motor. Press ENTER again to stop Main Drive Motor. Main Drive
Motor not starting indicates a problem in Main Drive Motor circuitry.

Clutch Test 1

Press ENTER to start Main Drive Motor and turn Feed Clutch ON. Press ENTER again to turn Feed
Clutch OFF. If Clutch does not engage there is a problem with Clutch circuitry.

Clutch Test 2

This test is designed to operate Clutch in an ON and OFF mode. Selecting this test and pressing ENTER
causes Clutch to actuate and de-actuate in sequence.

Sensor Test

Press ENTER to display state of Media Sensor. “Uncovered” displays when Sensor is NOT covered.
“Covered” displays when Sensor IS covered. Use a strip of paper inserted in Sensor area to test its

function. Failure to switch between the two messages indicates a problem in Sensor circuitry.

Power Supply Test

Press ENTER to display voltage reading of Main Power Supply. Nominal reading is between 13.5 and 14.5
volts. Power Supply may need adjusting to bring value within nominal range.

Encoder Test

Press ENTER to display current Encoder Count Reading. Move Exit Roller. If number does not increase,
an Encoder failure is indicated.

Keyboard Test

Press ENTER to test function of individual keys on keyboard. When a key is pressed, display shows key
name. To exit this test, power Printer OFF.

Ink Levels

Ink Levels in each of Cartridges are displayed as a percentage in this mode. This only displays properly if
operator resets system when a new Cartridge is installed.

16

FUNCTIONAL OPERATION

SECTION 3 – Functional Operation

Sequence of Operation

User Prepares the Printer

1. Selects number and color of Print Cartridges required and installs Cartridges in proper location.

2. Uses a single piece of media to set Sheet Separators.

3. Loads media and adjusts Side Guides to within 1/32" of media.

4. Stacks media in Feeder and adjusts Feed Ramp.

5. Turns Printer ON.

User Prepares Layout and Creates a Job

1. Selects the database and opens layout software such as Microsoft Word.

2. Creates a layout consisting of the variable data from the database using merge function.

SECTION 3

3. Creates a layout using fixed information (such as return address) and adds graphics as required.

4. Saves layouts.

5. Initiates Print function through File menu.

6. Selects whether job has an Overlay or not through Printer Driver Properties menu.

7. Clicks Print button to print job.

Printing Job

1. Once a job is sent to Printer and downloading is complete, system signals

Interface Board to turn Main Motor ON at preset speed.

2. ON LINE key lights up and Drive Motor starts to run, causing Media Transport Belt under

Printheads to turn.

3. Press ENTER and Feed Clutch turns, causing two sets of Feed Rollers to turn and feed media.

4. After media travels 2.5", it covers Photosensor and lowers its output. This turns Feed Clutch OFF

and stops Feed Rollers. Forwarding Rollers, driven by Transport Belts, move media to Printheads.
The 2.5" distance between Feeder and Photosensor paired with clutch action creates a 2.5" gap

between mailing pieces. Gap allows media to feed reliably and the variable data sent by the PC to
be positioned for printing.

17

SECTION 3

1.

ON LINE key – Indicator lights when data is sent to Printer and printing is ready to
begin. Also takes Printer off line to access Menu mode.

2.

+ key – In Menu mode, this key scrolls to next selection.

3.

ENTER key – Starts and stops printing.

4.

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

5.

RESET key – Resets Printer to “standby” state.

6.

- key – In Menu mode, this key scrolls to previous selection.

7.

MENU key – Puts Printer into Menu mode to access operator functions.

8.

TEST PRINT key – Puts Printer in Test mode and prints a sample copy to check

Printer’s output.

9.

OPERATOR (LCD) DISPLAY – Shows Printer’s status including menus, prompts and

error messages.

FUNCTIONAL OPERATION

Printing

Print Engine consists of three stationary Printheads and a rolling Belt which position the media.
Two Circuit Boards control the Printheads.

Printer Functional Description

1. Photosensor located in media path between Feeder section and Printing section senses lead edge of

media and signals Print Engine on Main Processor Board that mailing piece has arrived for
printing. Feed Clutch remains disengaged as long as a mailing piece is in view of Photosensor.

2. When mailing piece uncovers Sensor, Clutch engages Feed Rollers and next piece of media starts

moving toward Printer section. At this time, Print Engine downloads next variable record from PC
and gets ready for printing.

3. This cycle repeats itself as long as there is media in Feeder.

4. Either cycle stops when Feeder runs out of media, operator stops the process, or no records remain

to be printed.

Printer Control Panel

18

SECTION 3

FUNCTIONAL OPERATION

Printer Control Panel

When Printer is first turned ON, TEST PRINT key lights and display becomes active. At this point,
Printer is ready to print if it is connected to computer. Printer Control Panel Keys are used to access various
functions that help control Printer.

ENTER key

Used to start Printer printing under production situations. When Printer is placed in any Menu modes, use
ENTER to choose available options.

TEST PRINT key

Press TEST PRINT to place Printer in Test Print mode. “Working” appears in lower half of display.
Then display changes to “Enter to feed”. Pressing ENTER starts printing process and prints Test Print.
To stop feeding, press ENTER again.

To restore Printer to Normal “Ready” mode, press ON LINE key to take Printer off line, then press and
hold RESET until TEST PRINT key light blinks. Printer is then restored to its Normal “Ready” state.

Press and hold TEST PRINT to enter “Service Menu” where various Printer functions can be tested. To
exit “Service Menu”, turn Printer OFF, then ON. “Service Menu” is used primarily by service personnel
to diagnose problems. Use “+” or “-” keys to scroll through menu. Press ENTER to test the function. To
restore Printer to its Normal “Print” mode, turn it OFF then ON.

To check Ink Cartridge ink levels when you enter “Service Menu”, press “-” key. Amount of ink
remaining appears as a percentage in lower half of display window.

MENU key

Use to access Special Features built into Printer. Basic Features are accessed by pressing MENU.
Use “+” or “-” keys to access features.

Features available:

Clear Batch Counter – Pressing ENTER clears the number in upper right hand corner of display.
Resetting Counter is usually performed at the start of each job. Turning Printer OFF does not reset
this Counter.

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

Press Enter to Purge – Useful for clearing Printhead Nozzles when Printer has been idle for a time.
To activate Purge, press ENTER to feed one piece of media. To purge Printheads additional times,
press ENTER for each additional purge.

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

Address Recovery – In event of a Printer jam, recover up to 10 pieces by pressing MENU, then
stepping to “Address Recovery”. Press ENTER. “Enter: Recover 1 Piece” appears.
Use “+” key to select number of pieces to reprint (1-10), then press ENTER again to start printing
process. Once pieces are printed, press ONLINE key, then ENTER to resume printing job.

Print Enhancement – Press “+” or “-” keys to access this feature. Print Enhancement is used when
printing to ensure that Printhead Nozzles stay open and prevent loss of descenders on letters such as
“y” or “q” and accent marks that do not appear in every address. Pressing ENTER turns this function
ON or OFF. Function remains as changed until operator changes it again. Turning Printer ON and
OFF does not affect setting.

NOTE: Print Enhancement times out after 100 seconds if no media is going through Printer.
Once media starts printing, it will restart.

19

SECTION 3
FUNCTIONAL OPERATION

Automatic Feed – Turning feature ON causes Printer to start feeding once job is sent. If ON LINE
key is ON, Printer starts feeding and printing automatically. To press ENTER to start printing
process, turn this feature OFF. Turning Printer ON or OFF does not affect your selection.

Pause Type: – Allows Printer to respond to a “break mark” set in the database used in a given job.
“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 – Used for standalone desktop units not used in-line with other mailing equipment.

Printer stops feeding media for a set amount of time after it “sees” a “break mark”. This allows

time for operator to pack or separate that set of printed pieces before next set starts. Use “+” or “-”

key to access this feature. Press ENTER to turn this function ON or OFF.

Conveyor Speed Up – Used when Printer is used in-line with other mailing equipment (conveyors,
tabbers, etc.) When this feature is activated, Printer responds to “break mark” by sending a signal

to conveyor to speed up momentarily. This creates an obvious gap between end of one set of
pieces and beginning of the next. Use “+” or “-” keys to access this feature. Press ENTER to turn
this function ON or OFF.

Installing New Printheads – Printer can tell you when a Printhead is low on ink. To use this feature,
press MENU. Use “+” or “-” keys to highlight “Enter when head (n) is filled”. Press ENTER and
install a new Cartridge. Repeat for each Cartridge you install. When ENTER is pressed, display
changes to “Head (n) has a new cartridge”. To check Cartridge ink levels, press and hold TEST

PRINT until “Service Menu” appears. Use “+” or “-” keys to scroll to “Service Menu: Ink Levels,
100%100%100%”. This shows how much ink remains in Cartridge.

NOTE: This feature only works if Cartridges remain in original head where they were installed. If
you swap Cartridges from one head to another, levels will not be accurate.

A second set of menus is available in the display. To activate, press and hold MENU until “Setup Menu”
appears. Step through these items with “+” or “-” keys.

Total Count – Displays total number of prints that passed through Printer. Non-resettable.
BIOS Version – Press “+” key to display current BIOS version.

Bulk Ink – Not used on this model Printer. No provisions are made to install larger Cartridges.

+ / - key

In Menu modes, use these keys to step through options.

ON LINE key

If ON LINE key is ON, display shows “Printer Online / Waiting for Data” and light is lit. Printer is ready
to print the job when it is sent. To have Printer start printing immediately when job is sent, Automatic

Feed must be turned ON. If ON LINE key is OFF, display shows, “Printer Offline / ENTER for Paper
Feed”. In this condition Printer can feed paper. This is useful for setting up Feeder.

NOTE: If Printer is off line and a job is sent, display shows, “Printer Offline / Data Ready to Print”. To
print, press ON LINE key to put Printer on line. If data is sent and Printer is NOT set up to start
feeding automatically and ON LINE key is lit, then display shows
“Printer Online / ENTER to Start Feed”.

RESET key

Clears Printer memory and returns it to “standby” state. Key only functions if Printer is off line.

20

SECTION 3

FUNCTIONAL OPERATION

Purge While Printing

To Purge in the middle of a job:

Press ONLINE key to pause current job.
Press MENU, then step to “Press Enter to Purge”.
Press ENTER to start purge and press ENTER again to stop purge.
Press ONLINE, then ENTER to get back to normal printing.

NOTE: If a paper jam occurs during Purge: After Purge; use “Address Recovery” to get back to
normal printing. Otherwise you will lose records.

21

SECTION 3
FUNCTIONAL OPERATION

Printer Driver Properties

Printer Driver describes to Printer how to print your job. It controls Printer operation and allows you to
send fixed and variable text and graphics to Printer. Within your data management software is a “Print”
function. In that “Print” function is a Properties button. Through Properties you can control the Printer's
output. Use the Properties windows to customize Printer’s output:

To start printing, click File, then Print. “Print”
window opens. To print the job, click Print.
To use special features built into Printer Drivers,
clicking “Printer Properties” opens the Document
Properties Window.

Window below opens.

Layout Tab lets you select Portrait or Landscape orientation.
Paper/Quality Tab lets select your Paper Source or to set Invert Printing.

Clicking Advanced opens “Advanced Options” window.

22

AS-150

Resolution

Speeds Available

600 x 150 DPI

Low

600 x 200 DPI

Low

600 x 300 DPI

Low

600 x 600 DPI

Low

When Advanced Options window opens, there are
Paper/Output and Document Options to set up, change,

and adjust Printer.

Paper/Output

Paper/Output lets you select the size of media to be used.
NOTE: Maximum media size is 6.5" W x 9.25" L.

You can also set the number of copies to print.

SECTION 3

FUNCTIONAL OPERATION

Document Options

Document Options is used to set halftoning options, and

enable Print Optimizations. In Printer Features you can
set the resolution of Printer, set the language the printer
operates in, and add a delay to the feed to provide
separation between pieces.

Resolutions: Sets resolution of print quality. Changing
resolution to a higher number (e.g. 200 DPI to 600 DPI)

increases image quality.

23

SECTION 3
FUNCTIONAL OPERATION

Head Adjustment

Permits slight (0.001") adjustments to Printhead's
positions in relation to each other. Adjustment is used to
precisely align Printheads when printing graphics or type
that extends beyond width of one Printhead. Each Head
can be moved +/- 0.048" in 0.001" increments.

To move Printhead toward the lead edge of the layout,
move it in “-” direction.
To move Printhead away from the lead edge, move it in
“+” direction.

When Printer is turned OFF, changes made this way
return to original settings.

Feed Delay

Feed Delay can be used to put more space between

pieces as they are printed. This gives first piece printed
more time to dry before next piece is printed. Adjustment
range is in 0.1-second increments.

Inverse Printing

Paper/Quality Tab contains one element that is used to

reverse or invert printing on Printer.
In normal operation, printing is read from operator side

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

Clicking Paper/Quality tab, then “Invert Printing” in
Paper Source permits you to reverse printing direction
180 degrees. NOTE: Paper size is always “Max Print

Area” and Orientation is always “Portrait”. Do not
change them.

24

PC Board and Electrical Component Location

SECTION 3

FUNCTIONAL OPERATION

Non-Operator Side

Operator Side Left-hand Cover View

25

SECTION 4

WARNING!

ELECTRICAL ADJUSTMENTS ARE MADE WITH
PRINTER UNDER POWER. USE NONMETALLIC TOOLS
WHEN ADJUSTING POTENTIOMETERS ON PC BOARDS.

1. Unplug Printer and remove Non-

Operator Side Cover. (4 screws)

2. Loosen two screws [A] that mount

Main Drive Motor to Side Frame.

3. Move Motor up or down in slots until

you obtain at least a 1/8" deflection in
the Drive Belt.

4. Tighten two screws [A].

5. Reinstall Side Cover.

ADJUSTMENTS

SECTION 4 – Adjustments

Drive Belt Tension Adjustment

REQUIREMENT: To ensure Drive Belt is properly tensioned.
ADJUSTMENT:

26

1. Unplug Printer and remove Operator

Side Cover. (5 screws)

2. Loosen three screws [2] that mount

Encoder to Side Frame.

3. Move Encoder [1] up or down in slots

until you obtain at least a 1/8"
deflection in the Belt [3].

4. Tighten three screws [2].

5. Reinstall Side Cover.

Encoder Belt Tension Adjustment

REQUIREMENT: To ensure Encoder Belt is properly tensioned.
ADJUSTMENT:

SECTION 4

ADJUSTMENTS

27

SECTION 4

1. Remove Non-Operator Cover and connect

voltmeter probes to GND [1] and +15V [2] on
Interface PC Board. Turn Printer ON.

2. Adjust Potentiometer [3] on Power Supply

Module to obtain 14 VDC ± 0.1 V.

3. Turn Printer OFF, apply lacquer (such as

nail polish) to Potentiometer to prevent
adjustment from moving. Reinstall Cover.

INTERFACE PC BOARD

POWER SUPPLY MODULE

ADJUSTMENTS

Output Voltage Adjustment

REQUIREMENT: To provide proper output from Power Supply to Printer.
ADJUSTMENT:

28

1. Remove Non-Operator Cover and connect

voltmeter probes to GND [1] and TP2 [2] on
Interface PC Board.

2. Insert a BLACK media card over Sensor.

Turn Printer ON.

3. Adjust R2 Potentiometer [3] to read

0.5 VDC maximum.

4. Turn Printer OFF. Apply lacquer (such as

nail polish) to Potentiometer to prevent
adjustment from moving.

5. Reinstall Cover.

Media Sensor Adjustment

REQUIREMENT: To assure that Media Sensor senses media.
ADJUSTMENT:

SECTION 4

ADJUSTMENTS

29

SECTION 4

1. Remove Operator Cover. Leave ribbon cable

connected. Turn Printer turned ON.

2. Find the LCD Brightness Control

potentiometer [A].

3. Use a plastic flat-tipped screwdriver to turn

the potentiometer. Clockwise - brighter.
Counterclockwise - dimmer.

4. Adjust Display's brightness level as desired.

5. Turn Printer OFF. Apply lacquer (such as

nail polish) to Potentiometer to prevent
adjustment from moving.

6. Reinstall Operator Cover.

CONTROL PANEL PC BOARD

ADJUSTMENTS

LCD Display Adjustment

REQUIREMENT: To increase/decrease LCD Display intensity/brightness.
ADJUSTMENT:

30

SECTION 4

1. Disconnect Printer from power source.

2. Remove Operator Side Cover,

Non-Operator Side Cover and Rear Cover.

3. Reconnect Printer to power source and

turn it ON.

4. Turn brake tension adjusting screw [1]

clockwise until Brake exerts a drag on
Rear Feed Roller.

5. Load media and turn Printer ON. Press TEST

PRINT key, then ENTER to start feeding
media. Observe that only one piece of media
feeds at a time.

NOTE: If more than one piece feeds at a
time, increase tension by turning screw
clockwise. If Printer slows down, decrease
tension by turning screw counterclockwise.

6. Turn Printer OFF, disconnect from power

source. Reinstall Covers.

ADJUSTMENTS

Brake Adjustment

REQUIREMENT: To provide proper tension on Feed Shaft Brake Assembly for

proper feeding of media.

ADJUSTMENT:

31

SECTION 5
DISASSEMBLY – ASSEMBLY

SECTION 5 – Disassembly/Assembly Procedures

Tools Required

#2 Phillips head screwdriver 3/32" Allen wrench
#1 Phillips head screwdriver 5/32" Allen wrench

Basic Disassembly

Turn off power.

Disconnect Power Cord.

Disconnect Interface Cable.

32

Removing Side Guides

Remove four screws (two each side).

Removing Rear Media Support

Remove two screws [A] (as shown).
Lift assembly from machine.

Removing Print Cartridges

SECTION 5

DISASSEMBLY – ASSEMBLY

1. Lift Blue Lever.

2. Remove Cartridge.

3. Close Lever.

33

SECTION 5
DISASSEMBLY – ASSEMBLY

Replacing Separator Tips

1. Before replacing Separator Tips,

unplug Printer.

2. Loosen Separator Locking Knob [A].

3. Use a Phillips screwdriver and remove screw

holding metal cover over Separator [B].
Use screwdriver tip to pry Separator Tip out
of its holder.

4. Replace Separator Tip, reinstall metal cover

and screw. DO NOT overtighten.

34

SECTION 5

CAUTION

ALWAYS WEAR A GROUNDED WRIST STRAP WHEN WORKING
WITH ELECTRONIC BOARDS.

DISASSEMBLY – ASSEMBLY

Service Disassembly Procedures

NOTE: The following disassembly should only be done by a qualified, trained service representative.

OPERATOR SIDE COVERS

1. Remove two screws from top of Operator Side

Cover and one on side. Then remove two screws
from bottom of Cover.

2. Remove Cover carefully.

DO NOT pull Cover too far away from Printer as
it could damage Control Panel Cable.

3. Disconnect Control Panel Cable from

Control Panel PC Board.

4. Reassemble in reverse order.

35

SECTION 5
DISASSEMBLY – ASSEMBLY

Major Components under
Operator Side Cover:

1. Drive Motor

2. Encoder Drive Belt

3. Encoder

4. Main Power Supply

NON-OPERATOR SIDE COVER

1. Remove two screws from top of Non-operator

Side Cover. Then remove two screws from
bottom of Cover.

2. Remove Cover. Interface PC Board and Main

PC Board are under this Cover.

3. Main and Interface PC Boards: Main PC

Board attaches to Printer with four screws.
Interface PC Board attaches to Printer with
two screws. Unplug connectors and then
remove screws to remove PC Boards.

Major Components under
Non-Operator Side Cover:

1. USB/Interface PC Board

2. Print Head Driver PC Boards

3. Clutch Assembly

4. Power Switch/Fuse/Power

Receptacle Module

5. Drive Motor Pulley

6. Main PC Board

7. Power Supply

36

USB/INTERFACE PC BOARD

1. USB PORT

CONNECTION

2. CLUTCH

3. MOTOR

4. CONTROLLER

5. MEDIA SENSOR

6. 15VDC IN – Power input

for Interface PCB

7. USB INTERFACE

with Main PC Board

MAIN PROCESSOR PC BOARD

SECTION 5

DISASSEMBLY – ASSEMBLY

1. USB PORT

2. ENCODER

3. PRINTER DRIVER

PC BOARDS (2)

4. POWER INPUT

5. OPERATOR PANEL

6. INTERFACE

PC BOARD
CONNECTOR

37

SECTION 5
DISASSEMBLY – ASSEMBLY

REMOVING REAR COVER

1. Remove Rear Media Support, and

Operator and Non-Operator Side Covers.

2. Remove screws attaching Rear Cover

[A] to Side Frames. (3 per side).

3. Remove Cover.

REPLACING PRINTHEAD ASSEMBLY

1. Remove two Printhead Assembly mounting

screws [A] (1 on each side).

2. Disconnect Ribbon Cable [B] from each

Cartridge Holder. Take care to prevent
damage to ribbon cable or connectors.

38

3. Remove screw [C] to remove Media Sensor

Assembly [D] from Printhead Assembly.

4. Lift Printhead Assembly from

Carriage Holder.

5. Reassemble in reverse order.

SECTION 5

DISASSEMBLY – ASSEMBLY

REMOVING EXIT COVER

1. Remove Print Head Assembly, Operator

and Non-Operator Side Covers, and Main
Processor PC Board.

2. Remove screws attaching Rear Cover [A]

to Side Frames. (3 per side).

3. Remove Cover. (Transport Belt fits

through slot in Exit Cover.)

39

SECTION 5
DISASSEMBLY – ASSEMBLY

REPLACING SHEET SEPARATOR ASSEMBLY

1. Remove Media Side Guides (2 screws on

each side.)

2. Remove Operator and Non-Operator Side

Covers. (May also be necessary to

remove Main PC Board to access
mounting screws on Non-Operator side.)

3. Remove 3 mounting screws on

Non-Operator side [A].

4. Remove 1 mounting screw on Operator

side [B].

5. Lift Sheet Separator Assembly

out of Printer.

6. Reinstall in reverse order.

40

REPLACING CLUTCH

1. Remove Non-Operator Side Cover.

2. Remove Clutch Bracket [1]. Then loosen

Motor mounting screws [2].

3. Disconnect Clutch wiring harness [3] from

Interface PC Board (J4).

4. Lift Motor to loosen Motor Drive Belt [4].

5. Push Clutch in toward Frame and remove

locking pin [5]. Then remove Clutch [6] and
Drive Pulley [7].

6. Install in reverse order. (See SECTION 4 –

Drive Belt Tension Adjustment.)

SECTION 5

DISASSEMBLY – ASSEMBLY

REPLACING ENCODER OR ENCODER BELT

To Remove Encoder:

Remove Operator and Non-Operator Side Covers.
Disconnect Encoder wiring harness [1] from Main

PC Board. (Non-Operator side, J6 Encoder)
Remove three screws [2] mounting Encoder to

Operator Side Frame.
Remove Belt [3], then remove Encoder.

To Remove Belt:

Remove Operator Side Cover.
Loosen three screws [2] mounting Encoder to

Operator Side Frame.
Slide Encoder [1] up in slots to loosen Belt [3].
Remove Belt.

Reassemble in reverse order.
NOTE: Adjust proper tension on Belt.
(See “Encoder Belt Tension Adjustment” when
reinstalling Belt).

41

SECTION 5
DISASSEMBLY – ASSEMBLY

REPLACING DRIVE MOTOR, DRIVE BELT, MAIN PC BOARD,
AND POWER SUPPLY

1. Remove Operator Side Cover,

Non-Operator Cover, Main
PC Board.

2. Remove Main PC Board*:

Remove 4 mounting screws,
then carefully remove PC
Board. (Carefully disconnect

wiring if removing Board
completely.)

*Not necessary to remove
Operator Side Cover.

3. Remove Drive Motor** and/or Drive Belt*:

[A] Disconnect two wires from Motor to

Power Supply.
[B] Loosen two screws [1] that mount Motor
to Side Frame.
[C] Slide Motor in mounting slots and remove
Drive Belt* [2].
[D] To remove Motor: Remove two Motor
mounting screws [1], then remove Motor
(from Operator Side).

*Not necessary to remove Operator Side
Cover to remove Drive Belt.
(See “Drive Belt Tension Adjustment” when
reinstalling Drive Belt.)

**Not necessary to remove Main PC Board
to remove Drive Motor.

42

4. Remove Power Supply*:

[A] Disconnect wire harnesses and ground

wire from Power Supply.
[B] Remove four screws that attach Power
Supply to Printer Base.

[C] Remove Power Supply.
*Not necessary to remove Main PC Board

to remove Power Supply.

5. Reassemble in reverse order.

NOTE: Reattach ground wires.

SECTION 5

DISASSEMBLY – ASSEMBLY

43

SECTION 5
DISASSEMBLY – ASSEMBLY

REPLACING MAIN FEED ROLLER

1. Remove Non-Operator and Operator Side Covers.

2. Remove Main Feed Roller.

Non-Operator Side: Remove Clutch Bracket [1].
Loosen Motor mounting screws [2].

Disconnect Clutch wiring harness [3] from Interface
PC Board (J4).

Loosen Motor mounting screws. Lift Motor and remove
Motor Drive Belt [4] from Clutch Pulley.

Push Clutch in toward Frame and remove locking pin [5].
Remove Clutch [6] and Clutch Pulley [7].

Remove two screws from Bearing Housing. Remove
Bearing Housing and bearings.

3. Operator Side: Remove e-ring [8] on Brake Mounting

Stud. Slide Brake Assembly toward Roller.

4. Slide Feed Roller Shaft toward Non-Operator side then

remove Main Feed Roller Shaft through large opening on
Operator side.

5. Install in reverse order. Remember to install all belts

during reassembly. Readjust tension on Motor Drive
Belt (See “Drive Belt Tension Adjustment” when

reinstalling.)

44

DISASSEMBLY – ASSEMBLY

REPLACING REAR FEED, TRANSPORT AND EXIT ROLLERS

Rear Feed Roller [2], Transport Roller
[3] and Exit Roller [4] may be removed as

follows. (Instructions for removing Main
Feed Roller [1] are listed above.)

1. Remove Operator and Non-

Operator Side Covers, and Rear
Cover. (May also have to remove

Main PC Board.)

2. Transport Roller [3]:

Non-operator side:

Loosen Motor mounting screws to
loosen Motor Drive Belt. Remove
Belt from Transport Roller Drive
Pulley. Loosen set screw to remove
Drive Pulley [A].
Operator side:
Loosen Encoder mounting screws to
loosen Belt. Remove Belt from
Encoder Pulley. Remove set screw to
remove Encoder Pulley [B].

SECTION 5

3. Rear Feed Roller [2]:

Remove bearing housings from ends
of Rollers on Operator side [C].
Remove Roller through large opening
on Operator side.

4. Exit Roller [4]:

Remove bearing housings from ends
of Rollers on Operator side [D]. Slide
Roller through Transport Belt and
remove Roller through large opening
on Operator side.

5. Install in reverse order. Remember to install all belts during reassembly.

(See “Drive Belt Tension Adjustment” and “Encoder Belt Tension Adjustment” when reinstalling.)

45

SECTION 5
DISASSEMBLY – ASSEMBLY

REPLACING TRANSPORT BELT

1. Remove Print Head Assembly,

Operator and Non-Operator Side
Covers, and Main Processor PC Board.

2. Transport Roller:

Non-Operator side – Loosen Motor

mounting screws to loosen Motor Drive
Belt. Remove Belt from Transport Roller
Drive Pulley [D]. Loosen set screw to
remove Pulley.
Operator side – Loosen Encoder
mounting screws to loosen Belt.
Remove belt from Encoder Pulley.
Remove set screw to remove Encoder
Belt Pulley [A].

3. Exit and Transport Rollers:

Remove bearing housings [B] from side
frame. (Non-Operator side only).

4. Remove Exit and Transport Rollers [B]

through large opening in Non-Operator
Side Frame. NOTE: Carefully slide
Transport Belt [C] through gap in Exit
Cover. Remove Transport Belt from Exit
and Transport Roller Shaft Assemblies.

5. Reassemble in reverse order.

Remember to install all belts
during reassembly.
(See “Drive Belt Tension Adjustment”

and “Encoder Belt Tension
Adjustment” when reinstalling.)

46

SECTION 6

High Quality

50,000 addresses

Standard Quality

100,000 addresses

Letter Quality

150,000 addresses

Draft Quality

200,000 addresses

CAUTION

NEVER SHAKE, DROP, OR HIT CARTRIDGE AGAINST PALM OF HAND OR ANY
OTHER HARD SURFACE. SHAKING PRINT CARTRIDGE DOES NOT “MIX” INK AND
HITTING CARTRIDGE AGAINST A HARD SURFACE DOES NOT CLEAR NOZZLES.

THESE ACTIONS HURT PRINT QUALITY BECAUSE THEY ALLOW BUBBLES TO
FORM NEAR INK FIRING CHAMBERS. THESE BUBBLES PREVENT NOZZLES
FROM FIRING, CAUSING WHITE STREAKS IN PRINT IMAGE.

MAINTENANCE

SECTION 6 – Maintenance

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

Inkjet Cartridge

Inkjet Cartridges must be replaced when out of ink, when print quality is poor, or when purging and
cleaning have not helped image quality. Approximate life of HP 45 Inkjet Cartridges, (based on three lines
of 20 characters at 10-point size per address):

NOTE: These figures can vary depending on font selected.

Replace Inkjet Cartridge:

1. Open Latch Lever to remove used Cartridge from Cartridge

Holder. Pull Cartridge up and out of Holder.

2. Remove new Inkjet Cartridge from packaging. Take care not

to touch copper contacts, metal plate, or gold printhead.
Remove protective tape from Printhead.

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

Holder. Push down and toward contacts in Holder.

4. Make sure Cartridge is seated in Holder. Close Latch Lever to

secure Cartridge. DO NOT force Latch Lever into place.

5. Repeat Steps 1-4 above for remaining Cartridges.

47

SECTION 6

Ink in Cartridge may be harmful if swallowed.
Keep new and used Cartridges out of reach of
children. Discard empty Cartridges immediately.

Cloth should be:

Cloth should not be:

 Soft
 Fiberless, lint-free
 Moistened with Water

(Distilled is best but tap water works)

 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.)

Leave Cartridge in Printer for short periods of time, 1 day or less.
Next time that Printer is used, 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.)

Keep Printhead in an area that is relatively free of dust and paper particles that is not too dry.
Place Cartridges in a sealable plastic container with a damp sponge or towel to maintain

humidity and prevent Printhead from drying out.
When Cartridges are ready to be used again, Printhead will need to be cleaned.

Disposal

Cartridges 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 usually removes ink off of hands.

Cleaning Printhead

Maintain good print quality by keeping Printheads clean. During printing, ink spray, paper fibers, and dust
build up on Printheads. This build-up eventually degrades print quality. If you notice problems with print
quality, or to just prevent a build-up from occurring, wipe Printhead with a wet fiberless, lint-free cloth.

Wipe slowly across long-axis with Printhead
facing down (as shown).
DO NOT apply excessive force, as this could
scratch Nozzle surface.

48

SECTION 6

MAINTENANCE

Purging Nozzles

If Printhead sits inactive for a period of time, ink may dry in the Nozzles. Printing may not remove these
“ink plugs” from the Nozzles. White streaks appear in printed text or graphic. In improve print quality,
these ink plugs need to be forced out or purged. A Purge routine is built into Printer. Access from Printer
Control Panel using MENU key.

If this does not solve the problem:

1. Wipe Printhead with a wet cloth as described in “Cleaning Printhead” on previous page.

2. Perform Purge from Printer by pressing MENU, then “+” key. Load media and press ENTER to

purge. Repeat if necessary.

3. Wipe Printhead again with a moist cloth.

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

Jams in Printer

If a jam occurs, STOP the Printer. Missed addresses can be recovered at computer after job is printed.
No data will be lost.

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 Printer.

4. Envelopes caught under 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 Printheads to gain access to jammed media. Take care in

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

2. Use “Address Recovery” to recover any lost addresses.

3. Restart job by putting Printer back to STAND BY. Resume printing by Pressing ENTER button on

Control Panel.

Replacing Sheet Separators

Sheet Separators ensure separation of pieces as they are fed. They wear and must be replaced periodically.
If you experience double sheet feeding and cannot adjust Separators to prevent it, replace them.

Replacement is not difficult:

1. Turn OFF and unplug Printer.

2. Release Separator-by loosening knob [A] and move

Media Side Guides to maximum opened position.

3. Lower Separators so they touch Feed Roller.

4. Remove screw [B] and Separator Support [C]. Then pry

Separator [D] out of Holder.

5. Install a new Separator and reinstall the Separator

Support and screw.

49

SECTION 6

WARNING!

PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED
REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING
ANY MAINTENANCE, DISCONNECT PRINTER FROM ITS POWER SOURCE!

CAUTION

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

MAINTENANCE

Cleaning

Printer must be cleaned regularly of accumulated paper dust and ink. Depending on types of media run,
paper dust may accumulate within Printer and on Transport. Before cleaning Printer, unplug it from power
receptacle and remove covers.

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

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

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

contain plastic-harming solvents.

Feed Rollers and Forwarding Rollers

Feed and Forwarding Rollers can become glazed with paper lint and ink from media.
Clean regularly with a mild abrasive household cleaner on a damp cloth.

Avoid using solvents on Rubber Rollers.

Cleaning Media Sensor

Periodically check Media
Sensor, (located under Inkjet
Cartridge Holder).

1. Remove two screws

attaching Holder to
Side Frame [A] (one

on each side of
Holder).

2. Carefully lift up and

turn Holder over.

DO NOT damage or
strain Ribbon Cables
or Media Sensor
wiring. Use a vacuum with a soft brush

attachment or dry compressed air to remove any dust or debris from Sensor [B].

50

PRINT TECHNOLOGY

Inkjet, Three HP 45 High Capacity Inkjet Cartridges

BELT SPEED

110 ft./minute – 22 in./second (33.5 m/minute – 55.6 cm/second)

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

1.5" x 9.25" (38.1 mm x 235 mm)

PRINT ORIENTATION

Normal and Reverse

INK MONITOR

Via Display

FONTS

All TrueType fonts available on PC

GRAPHICS, LOGOS, AND
BARCODES

Allows printing of graphics, logos, and barcodes

MEDIA SIZE
(Min. to Max.)

Length: 4" to 9.25" (101.6 mm to 235 mm)
Width: 2.125" to 6.5" (54 mm to 166 mm)

MEDIA THICKNESS

Up to 0.020" (0.51 mm)

FEEDER CAPACITY

Up to 300 envelopes

MEMORY

12 MB

PRINT COLORS

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

INK

Water-based, may require drying assistance for coated stock

SOFTWARE

WindowsTM Printer Drivers for WindowsTM

DIAGNOSTICS

Built into firmware

FIRMWARE UPDATE

Via PC interface in flash PROMS.

PC INTERFACE

USB

COUNTERS

One operator resettable job counter, one permanent lifetime counter

DIMENSIONS

18.5" H x 14" L x 13" W
(47 cm H x 35.6 cm L x 33 cm W)

WEIGHT

32 lbs. (14.5 kg.)

ELECTRICAL

115VAC or 240VAC 50/60 Hz

APPENDIX A – Printer Specifications

APPENDIX A

All Specifications Subject To Change Without Notice

51

Red Inkjet Cartridge

Green Inkjet Cartridge

Blue Inkjet Cartridge

Yellow Inkjet Cartridge

Versatile Black

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

APPENDIX B

APPENDIX B – Supplies

The following supply items are available from your Distributor:

Supplies

52

INDEX

A

Adjustments .................................................... 26

Brake ............................................................ 31

Drive Belt Tension ....................................... 26

Encoder Belt Tension ................................... 27

LCD Display ................................................. 30

Media Sensor ................................................ 29

Output Voltage ............................................. 28

Appendix A

Specifications ............................................... 51

Appendix B

Supplies ........................................................ 52

Assembling Printer ............................................. 2

Assembly, Printer ............................................. 32

B

Belt

Adjustment, Drive Belt ................................. 26

Adjustment, Encoder .................................... 27

Encoder ......................................................... 41

Main Drive ................................................... 42

Transport ...................................................... 46

BIOS Manager .................................................... 8

Brake, Feed Shaft ............................................. 31

C

Cleaning

Feed Rollers .................................................. 50

Forwarding Rollers ....................................... 50

Media Sensor ................................................ 50

Printer ........................................................... 50

Printheads ..................................................... 48

Clutch, Replace ................................................ 41

Connecting

Computer ........................................................ 4

Printer ............................................................. 4

Contents of Packaging ........................................ 2

Control Panel ............................................ 18, 19

Display.......................................................... 18

Covers

Remove Exit ................................................. 39

Remove Non-operator Side .......................... 36

Remove Operator Side ................................. 35

Remove Rear ................................................ 38

D

Disassembly, Printer ......................................... 32

Display

Control Panel .......................................... 18, 30

Disposal, Inkjet Cartridges ............................... 48

Drive Belt, Main ............................................... 42

Drive Motor, Replace ....................................... 42

E

Electrical Components Location .......................25

Encoder

Belt ...............................................................41

Belt Adjustment ................................ ............27

Replace .........................................................41

ENTER Key ......................................................18

Exit Roller, Replace ..........................................45

F

FAULT Indicator ..............................................18

Feed Ramp, Remove .........................................33

Feed Rollers

Cleaning ........................................................50

Replace .........................................................44

Feed Set Up ....................................................... 6

Feeding Problems, Troubleshooting .................10

Forwarding Rollers

Cleaning ........................................................50

Replace .........................................................45

Functional Operation, Printer ...........................17

I

Indicator, FAULT ................................ .............18

Inkjet Cartridges

Disposal ........................................................48

Install ............................................................. 5

Maintenance..................................................47

Replace .........................................................47

Storage ..........................................................48

Install

BIOS Manager ............................................... 8

Inkjet Cartridges ............................................ 5

Media Support ............................................... 3

Printer ............................................................ 2

Printer Driver ................................................. 7

Rear Media Guide .......................................... 3

Side Guides .................................................... 2

Interface Communication Problems .................. 9

J

Jams in Printer ..................................................49

Jams, Remove Media ........................................49

K

Key

- Scroll Previous ...........................................18

+ Scroll Next .................................................18

ENTER .........................................................18

MENU ..........................................................18

ON LINE ......................................................18

RESET ..........................................................18

TEST PRINT ................................................18

L

LCD Display .....................................................18

LCD Problems, Troubleshooting ......................10

INDEX

M

Maintenance .................................................... 47

Cleaning........................................................ 50

Injet Cartridge ............................................... 47

Printer Jams .................................................. 49

Printheads ..................................................... 48

Sheet Separators ........................................... 49

Media Sensor

Adjustment ................................................... 29

Cleaning........................................................ 50

Media Support

Install .............................................................. 3

Remove ......................................................... 33

MENU Key....................................................... 18

Motor, Drive ..................................................... 42

O

ON LINE Key .................................................. 18

Operator Display .............................................. 18

P

PC Board

Control Panel ................................................ 30

Interface .................................................. 28, 29

Location ........................................................ 25

Main PC Board ............................................. 42

Main Processor ............................................. 37

USB/Interface ............................................... 37

Power Problems .................................................. 9

Power Supply, Replace ..................................... 42

Print Cartridges

Remove ......................................................... 33

Print Content Incorrect, Troubleshooting ......... 15

Print Placement Problems ................................. 14

Printer

Adjustments .................................................. 26

Assembling ..................................................... 2

Assembly/Disassembly ................................. 32

Brake Adjustments ....................................... 31

Cleaning........................................................ 50

Clutch ........................................................... 41

Connecting ...................................................... 4

Control Panel .......................................... 18, 19

Disassembly/Assembly ................................. 32

Drive Belt Tension Adjustment .................... 26

Encoder Belt Tension Adjustment ................ 27

Feed Ramp, Remove .................................... 33

Functional Operation .................................... 17

Install .............................................................. 2

Jams .............................................................. 49

LCD Display Adjustment ............................. 30

Maintenance ................................................. 47

Media Sensor Adjustment ............................ 29

Operator Display .......................................... 18

Output Voltage ............................................. 28

Package Contents............................................ 2

PC Board & Electrical Components ............. 25

Purge While Printing ....................................21

Sequence of Operation ..................................17

Side Guides, Remove ...................................33

Specifications................................................51

Supplies ........................................................52

Troubleshooting ............................................. 9

Printer Driver

Install ............................................................. 7

Properties ......................................................22

Printhead Assembly, Replace ...........................38

Printheads

Cleaning ........................................................48

Install ............................................................. 5

Nozzles, Purging ...........................................49

Printing Problems, Troubleshooting .................12

Purge While Printing ........................................21

Purging Nozzles, Printhead ..............................49

R

Rear Feed Roller, Replace ................................45

Rear Media Guide, Install .................................. 3

Remove

Exit Cover .....................................................39

Feed Ramp ....................................................33

Media Jams ...................................................49

Non-Operator Side Covers ...........................36

Operator Side Covers ....................................35

Print Cartridge ..............................................33

Rear Cover ....................................................38

Side Guides ...................................................33

Replace

Clutch ...........................................................41

Drive Motor ..................................................42

Encoder .........................................................41

Encoder Belt .................................................41

Exit Roller ....................................................45

Feed Rollers ..................................................44

Forwarding Roller .........................................45

Inkjet Cartridges ...........................................47

Main PC Board .............................................42

Power Supply ................................ ................42

Printhead Assembly ......................................38

Rear Feed Roller ...........................................45

Sheet Separator Assembly ............................40

Sheet Separator Tips .....................................34

Sheet Separators ...........................................49

Transport Belt ...............................................46

Transport Roller ............................................45

RESET Key ......................................................18

S

Sequence of Operation ......................................17

Service Diagnostic Tests ..................................16

Set Up

Feed ............................................................... 6

INDEX

Sheet Separator

Assembly, Replace ....................................... 40

Replace ......................................................... 49

Tips, Replace ................................................ 34

Side Guides

Install .............................................................. 2

Remove ......................................................... 33

Software Problems, Troubleshooting ............... 15

Specifications, Printer....................................... 51

Storage, Inkjet Cartridges ................................. 48

Supplies, Printer ............................................... 52

T

TEST PRINT Key ............................................ 18

Transport Roller, Replace ................................. 45

Troubleshooting

Feeding Problems ......................................... 10

Interface Communication Problems ............... 9

LCD Display Problems ................................. 10

Power Problems .............................................. 9

Print Content Incorrect ................................. 15

Print Placement Problems ............................. 14

Printing Problems ......................................... 12

Service Diagnostic Tests .............................. 16

Software Problems........................................ 15

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