ASTRO. AstroJet 2000 High-Speed Inkjet Printer. Installation, Operating, and Parts Manual

ASTRO AstroJet 2000 High-Speed Inkjet Printer Installation, Operating, and Parts Manual

REQUIREMENTS 1. An IBM or Compatible Pentium 100 Megahertz PC or better. 2. Windows 95 or 98 installed. 3. A minimum of 10 Megabytes of free hard disk space. 4. At least 16 Megabytes of RAM. 5. A 2X CD ROM or better. 6. An 800 X 600 SVGA Monitor or better. 7. Parallel (Centronics) printer cable, no longer than 6 feet. 8. The Parallel Port must be set to the EPP (Enhanced Parallel Port) setting in the CMOS of the computer. SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE ASTROJET 2000 SYSTEM. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: 1. Keep hands, hair, and clothing clear of rollers and other moving parts. 2. Always turn off the machine before making adjustments, cleaning the machine, or performing any maintenance not covered in this manual. 3. Turn power off, including conveyor when not in use. 4. Keep this manual with the printer for future reference. 5. If you have any questions contact your local Astro Machine Corporation Distributor. CAUTION THIS EQUIPMENT MUST BE CONNECTED TO A PROPERLY GROUNDED OUTLET. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK! This manual is intended solely for the use and information of Astro Machine Corporation, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither Astro Machine Corporation nor any of its agents or employees shall be responsible for any inaccuracies contained herein. Hewlett-Packard is a registered trademark of Hewlett-Packard Corporation. Windows 95 and Windows 98 are registered trademarks of Microsoft Corporation. IBM is a registered trademark of International Business Machines. All other TradeMarks are the property of their respective holders. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the Publisher.

TABLE OF CONTENTS Section 1 Introduction 1 Section 2 Getting Acquainted 3 Components 3 Feeder Section 4 Printer Section 4 Key Pad Definitions 5 Operator Display Screen and Menu 7 Section 3 Installation and Setup 9 Choose a Location 9 Install the Inkjet Cartridge 9 Plug in the AstroJet 2000 10 Setting up the AstroJet 2000 10 Install Software on the Computer 11 Section 4 Operating the AstroJet 2000 13 Software Tutorial 13 Bundle and Bag Break 25 Running a Job 26 Printing Tips 28 Databases 29 Section 5 Maintenance 33 The Inkjet Cartridge 33 Jams in the AstroJet 2000 Printer 36 Cleaning 36 Section 6 Trouble Shooting Guide 39 Inkjet Cartridges 39 AstroJet 2000 Printer 40 AstroJet 2000 Software 41 Appendices 43 Specifications 43 Supplies and Optional Hardware 44 i

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Section 1 Introduction Section 1, Introduction, describes how this manual is arranged. The manual covers the AstroJet 2000. Section 2, Getting Acquainted, introduces the AstroJet 2000 System and describes the major components, controls, indicators, and important areas with which the user or operator should be familiar. Section 3, Installation and Setup, describes how to install the software and get the AstroJet 2000 System ready for printing. Section 4, Operating the AstroJet 2000, describes how to set up the AstroJet 2000 System and Software to run a particular addressing job. Section 5, Operator Maintenance, shows how to replace inkjet cartridges, how to safely and quickly clear paper jams, and how to care for your AstroJet 2000. Also, covered in this section are tips and suggestions that will help you increase efficiency and avoid problems. Section 6, Trouble Shooting Guide; gives advice on how to remedy problems that may occur during use of the AstroJet 2000. Appendices, is where important but infrequently used information is presented. The appendices are arranged as follows: Appendix A, Specifications, lists the more important AstroJet 2000 characteristics, e.g., electrical, physical, etc. Appendix B, Supplies and Optional Hardware, presents a list of supplies for the AstroJet 2000 System and optional equipment which will further enhance the operation of the AstroJet 2000. 1

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Section 2 Getting Acquainted The AstroJet 2000 is a high-speed printing and addressing systems that can print addresses, bar code, return addresses, bitmapped graphics, and special messages using TrueType scaleable fonts simultaneously on up to 30,000 postcard (3.5 X 5.5 inch) mail pieces per hour. The AstroJet 2000 has its own built in top loading feeder. Before getting into the operation of the AstroJet 2000, there is some basic information necessary for its efficient and problem-free use. To understand and operate the trouble free AstroJet 2000 System lets look at the two main areas on the printer. 1. Components 2. Operator Display Screen and Menu Components The main areas of the AstroJet 2000 printer are shown in the following drawing. These areas are described in the paragraphs that follow. 3

Feeder Section The media to be printed and addressed is loaded into the feeder section of the AstroJet 2000. It is fed into the printer section as required at the speed selected by the operator from the AstroJet 2000 Software Control Panel. The feeder is adjustable for a wide variety of media. Printer Section The Printer is the most important part of the AstroJet 2000. It is here that the address and other information are printed on the media. Two important features of the printer that you should become familiar with are: The Control Panel The Medial Thickness Adjustment The Control Panel The control panel is on the front of the printer and contains the controls and indicators (described in the following table) used to set up and operate the AstroJet 2000. The Media Thickness Adjustment The Media Thickness Adjustment is to the left of the ON LINE button on the control panel. It adjusts for media thickness and is turned counterclockwise for thin media, and clockwise for thick media. 4

Keypad Definitions CONTROL / INDICATOR OPERATOR DISPLAY DESCRIPTION Indicates AstroJet 2000 status including menus and error messages. Any display readout indicates that the unit is ON. ON LINE When this indicator button is lit, the AstroJet 2000 is ready to accept data from your computer and begin printing. Turns the printer on and off line. PREVIOUS NEXT SELECT/FEED TEST RESET STANDBY When in menu mode, will scroll to the previous selection. When in select mode, will scroll through choices. When in menu mode, will scroll to the previous selection. When in select mode, will scroll through choices. Locks and unlocks selection when in the menu mode. In the operational mode it starts and stops the feeder. NON FUNCTIONING. NON FUNCTIONING. Toggles the printer between the ON LINE and STANDBY modes. Interface and Power Panel While facing the control panel of the AstroJet 2000, the power panel can be found on the right of the machine. It contains the main power switch, fuse, power cord receptacle, circuit breaker, and accessory plug. At the rear of the printer you will find the Centronics parallel port. 5

Printhead Carriage The AstroJet 2000 has five printheads. The heads are arranged in the following configuration: Head 1 is on a separate rail and can be positioned between the other two banks of heads. Heads 2 and 3 are banked together as are heads 4 and 5. These heads share the same rail assembly. The AstroJet 2000 Layout software shows the position of the heads and how they are banked together. For more information on this feature, please check Section 4 Operating the AstroJet 2000 or the AstroJet 2000 software help program. You can move the various printing banks from side to side to position the information properly on the media with the following restrictions: Head 1 prints a band 1/2 wide and may be positioned anywhere within a range of 9-3/8 on the media. It can be positioned next to and stitched to Head 2 or Head 4 to form a printing band 1-1/2 wide. It should not be positioned next to Head 3 or Head 5, as the exit rollers will cause tracking on the printing from those respective heads. Heads 2 and 3 and Heads 4 and 5 form a continuous printing bank of 1 each. The maximum distance that these two banks can be placed apart is 9-3/8. The minimum distance they can be placed with respect to each other is 1-3/4. When the banks are placed that distance from each other Head 1 can be placed between them. It is recommended that Head 1 be placed as close to Head 4 under these circumstances if a 1-1/2 printing width is required. A minimum of a 1/4 margin should be left at the top and bottom of the media to insure good feeding and print quality. In addition a 1/4 margin should be left at the leading and trailing edges of the media. 6

Media Sensor The media sensor is located behind the front feed plate just before the printhead carriage. It senses the leading edge of the media and communicates this to the software. It is very important that the media sensor be kept clean. Operator Display Screen and Menu When you first turn on the AstroJet 2000, you see the AstroJet 2000 welcome screen, and the STANDBY key is lit. MENU To access the Menu press the STANDBY key to put the printer in the on line mode and then press the ON LINE key to take the print off line. This action will place the AstroJet 2000 in the MENU mode and permit access to the following settings and adjustments: Left Margin Setting Purge Counter Print Speed 7

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Section 3 Installation and Setup Before using the AstroJet 2000 Printer for the first time, the following procedures must be performed: Choose a location for the AstroJet 2000 Printer Install the inkjet cartridges Plug in the AstroJet 2000 Set up the AstroJet 2000 Install the AstroJet 2000 software Set up the transport Adjust for media thickness Position the printed output on the media Choose a Location The AstroJet 2000 should be attached to the computer with a parallel printer cable not more than 6 feet in length. Use a grounded electrical outlet. DO NOT USE AN ADAPTER PLUG! Do not use outlets that are controlled by wall switches. Do not use an outlet that shares the same circuit with large electrical machines or appliances. Protect the AstroJet 2000 from excessive heat, dust, and moisture avoid placing it in direct sunlight. Install the Inkjet Cartridges NOTE: For optimum image quality during the run, refer to Cleaning the Printhead on page 34. HP 51645A Inkjet Cartridges The AstroJet 2000 can be equipped with 5 inkjet cartridges to give a total printing area of 2 1/2 inches. The cartridges are installed as follows: Remove the inkjet cartridge from its packaging, taking care not to touch the copper contacts, the metal plate, or the gold printhead. Remove the protective tape from the printhead. The cartridges are held in place by vertical brackets mounted on the inkjet cartridge holder. With the cartridge s gold printhead pointing toward the rear of the unit and while holding it vertically, slide the bottom edge of the cartridge down along the front of the bracket until it slides partly into place. 9

At this point press the upper part of the cartridge toward the bracket until it clicks completely into place under the metal spring secured to the bracket. (See the diagram below.) Repeat the above for the remaining cartridges. Plug in the AstroJet 2000 Make sure that the main power switch of the AstroJet 2000 Printer is in the OFF position. 1. Connect one end of the power cord to the rear of the AstroJet 2000 in the corresponding receptacle. 2. Plug the other end into a 120-Volt AC, 60 Hz. Grounded outlet. CAUTION DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT THE ASTROJET 2000 PRINTER TO THE WALL RECEPTACLE! Set up the AstroJet 2000 Connect the Printer In order for your computer and the AstroJet 2000 to work together, you will need to connect them with a parallel cable. The cable is connected between the parallel port on the computer and the printer. The cable used to connect the AstroJet 2000 to the computer must not exceed 6 feet long. Set up the Feeder NOTE: The AstroJet 2000 is supplied with two types of sheet separators. A soft tip which is installed on the unit when you receive it is for use with standard 20 # paper and a hard tip for thicker media. Refer to the drawing below for the location of the separator tips. To change them release the separator-locking lever on the left side of the feeder and lower the separators. Remove the screw attaching the tip to the separator. Remove the existing 10

separator and install the new one. Take care not to loose the mounting screw in the machine. The following steps will assist you in setting the feeder portion of the AstroJet 2000: 1. Place one piece of media on the feeder table move the side guides out to their extreme open position. Release the separator-locking lever located on the left side of the feeder and raise the separators to their up and locked position. 2. There are four separators on the feeder. Use the two center separators for narrow media and the two end separators for wide media. Place the media under the separators and lower the separators so that they rest on the media. 3. Move the locking lever up to lock the separators in place. 4. Adjust the side guides to the width of the media and set the back guide so that it just touches the back of the media. 5. Turn the AstroJet 2000 on and then turn the media thickness knob to set the initial print head height as follows: Media Thickness Dial Setting.004 to 1/32 0 to 2 1/32 to 1/16 2 to 3 1/16 to 1/8 3 to 7 1/8 to 1/4 7 to 10 NOTE: These are initial settings to check the media feed. It may be necessary to adjust the MEDIA THICKNESS control to optimize the print quality 6. Press the STAND BY switch then press the SELECT/FEED switch, to test feed media. Install the Software on the Computer The computer that is supplied with your AstroJet 2000 System is optimized for efficient, trouble free operation. It is equipped with a network card (10-base T) to enable you to connect the AstroJet 2000 System to your existing network. Contact your system manager or dealer for installation AstroJet 2000 Software Installation 1. Install the CD in the computer. The CD should start automatically. If it does not click on Start button, then select Run. Type D:\Setup.exe (where D is the CD drive) and click OK. 2. The AstroJet Setup Menu will appear on your screen. It contains five options. Install Printer Software Read the Manuals Browse this CD Install Adobe Acrobat This is version 4.0 of Adobe Acrobat for reading and printing the Operator Manuals. 11

www.astromachine.com This is a link to our web site if you are connected to the Internet. 3. Click on Install Printer Software and then click on the AstroJet Printer model you wish to install. Follow the instructions on screen. Use default settings only. Note: If the message Setup Can Not Execute the Following Program: C:\ProgramFiles\Astrojet III\DeReg.exe or The following file is in use and can not be updated appears, click on Cancel button and continue with the installation. 4. If this is a new printer installation (not a software update) skip #6. Your software and firmware are installed and configured. 5. If this is software and firmware update you must download new bios to the printer. Connect printer to the computer and turn it on. Open AstroJet Control Panel and click on Advanced button then Update BIOS button. Follow instructions on screen. 6. Be sure to fill out and mail registration sheet to insure that you will be notified of all updates to the software and firmware. 12

Section 4 Operating the AstroJet 2000 Once the AstroJet 2000 software has been installed on the computer and the AstroJet 2000 printer has been supplied with media and ink cartridges, it is ready to print. Using your existing database, you create a Layout and Job files with the AstroJet 2000 software. The computer sends the job to the AstroJet 2000 printer. The AstroJet 2000 then prints the Job with both the addresses and other information you input in the layout. This section explains how the AstroJet 2000 System is used and is divided into five main categories: Software Tutorial Starting Up Preparing a Job Running a Job Printing Tips Software Tutorial Description of the Software The following is a brief tutorial on how to use the AstroJet Printer Software. A more detailed description of the various parts of the software may be found in the AstroJet Help menu that accompanies the software. It is assumed that you have experience in navigating through Windows. If you are new to computers or are not familiar with Windows many books are available that can help you. The software is divided into two parts, The AstroJet Layout Editor and the AstroJet Control Panel. When the AstroJet Printer Software was loaded on the computer, the two icons shown below were placed on the desktop. The AstroJet III folder was placed in your Program Files. This is the place where all of the AstroJet software resides. The AstroJet Layout Editor, AstroJet Control Panel and Help files are located in this folder along with the AccuJet Data folder. The AccuJet Data folder contains several additional folders. These folders contain all of the information required by the AstroJet Printer Software to create and run the job. The file structure is illustrated below: 13

AstroJet III AccuJet Data Bios Databases Fonts Jobs Logos Projects The latest version of the system Bios is stored here. This folder is used to store your databases. When a job is printed from the AstroJet Control Panel the fonts and logos used for that job are rendered in a format that the AstroJet Image Blaster Printer can use. These rendered fonts and logos are stored in this folder for future use when the job is run again. The Jobs folder shows information about the job such as total number of records, the template used to layout the job, resolution, and last record processed. The Logos folder can be used to store any logos in Windows.BMP format that are used with the job. This folder stores all of the information necessary for the software to format and run the job. The AstroJet Layout Editor is used to create the job. The AstroJet Control Panel is used to send the job you created to the AstroJet Printer. All jobs are designed in the AstroJet Layout Editor. This is where we will begin with this tutorial. Starting the Software Double click on the AstroJet Layout Editor icon to open the program and we will begin. The first screen that appears is the Welcome to the AstroJet Layout Editor screen. There are three choices, "Create a new template?", "Modify an existing template?, and Modify an existing template with a replacement database?. Click on the Create a new template? and then click on the Next>> button. The Layout Wizard Select Database screen will appear. Click Next>> to continue. The Open window is used to search and select the database. The Databases folder in the AstroJet software is the default. You should store your databases in this folder. Select the database type from the drop down menu. Next, select the appropriate database and click Open to open the database. For more information on databases and how to prepare them for the AstroJet refer to DATABASES at the end of this section. 14

The Wizard will switch to the Database View (file name). The first record of the database will be displayed. There is a series of arrows just below the record. These can be used to step through the records as follows: Move 1 Backward Move 10 Backward Move 10X Backward Move to First Record Move 1 Forward Move 10 Forward Move 10X Forward Move to Last Record Record Position Record Number Click Next>> and the Layout Wizard Stock Properties window will open. Select the size and/or type of stock that you will be printing on. There are many standard envelopes available. Select one by using the drop down menu next to Standard or select Custom and enter the Width and Length of the piece. You may save the custom size by giving it a name and clicking on Save As. When you have completed this step, click Finish. The Layout Editor Untitled screen will appear. When the software was installed on the computer, the printing banks were set up according to the AstroJet 2000 s configuration. The white lines in the display represent the print cartridges and how they are positioned in the printer. The AstroJet 2000 has five print cartridges. The print cartridges are arranged on two sets of rails as follows: 15

Printhead 1 may be connected in the software to either to head 4 or head 2. This will permit you to print up to 1.5 inch wide on the media. There are some restrictions as to the placement of printhead 1, however due to the guide rollers in the printing section. If in doubt run a test before beginning the job. Before continuing, spend a little time exploring the Layout Editor Untitled screen. The AstroJet 2000 uses five print heads. To eliminate the unused heads, click on Setup, then Print head. Click on the boxes in the window for the head positions that are not used (heads 6, 7, and 8) and de-select them. Then click OK. The bands in the layout that are remaining represent the print heads on your particular model of AstroJet Printer and are properly banked together. In the top line of the display, you see the following items: File View Fields Setup Tools Help 16

Each of these controls a drop down menu that permit choices that perform the tasks required to set up the job. The second line contains icons that represent those tasks. The drop down menus duplicates the function of some of the icons. It really depends on how you wish to use the software. For the purpose of this tutorial, we will use the icon buttons to set up a sample job. Setting up the Job When you first opened the job you set the size of the piece. The piece size may be changed at any time during or after the setup of the job by clicking on Setup and then Envelope Size or by clicking on the Envelope Size icon on the menu bar. Click on this icon and the Envelope Properties window will open. Select either Standard or Custom. Press the OK button. If you choose Custom you may use any number or fraction from 3 inches up to 15 inches in width and from 5 inches up to 17 inches in length. When you press the OK button, the Layout screen will adjust the view of the media to the size selected automatically. If you intend to use the Custom size again, save it by giving it a name and clicking on Save As next to Custom. You must enter a name for this feature to work. Refer to the screen image on page 18. The corresponding print banks will show on the screen in white. These banks can be moved together or separately in sets in the same way that they can be changed on the printer. The maximum printing area on the Image Blaster with 6 heads is 3 inches. To the right of the template image are numbers. These correspond to the printheads and are marked with the same numbers on the AstroJet Printer. Also, to the right is a line. This guideline can be moved to any point on the layout to assist you in lining up the fields or information that you will be adding. To get all of the information to line up on a particular bank move the line close to the position desired for the lines and right click on the mouse while the guideline is selected with the mouse pointer. The next step is to build the job on the layout. When you click on the Text Field Properties icon the Layout Editor Text Field Properties window will open. This window permits you to enable up to 24 lines of information and data with up to 4000 characters per Text Field. Enable one button for each line of type style in the layout. If you wish to make additions, deletions, changes in the style of type, or the number of lines, you can click on this icon anytime during the setup or before you run the job to make changes. For the purposes of this tutorial, we are going to enable the first 4 lines and set them up according to the picture. Line 1 will be for the database address. Line 2 will be for the company name in the return address. Line 3 will be for the rest of the return address. Line 4 will be for an additional message on the media. 17

After enabling the lines, select the style of font, size of type, and whether the type should be bold, italicized, underlined or struck through. The down arrow will permit you to access the other sixteen lines of data that are available for use. Click OK to continue. The software returns to the Layout Editor screen and the data selected will be displayed at the bottom right hand corner of the media layout called the blotter area. Use the mouse to move each line into the general area of the layout where they will be finally positioned. Once you have done this, place the cursor on the field that will contain the variable address from your database and double click on the left mouse button. The following window will appear on the screen. This window allows you to layout the variable address fields in their proper order. Use the drop down box in the upper right hand corner of the window to add fields from your database in their appropriate position in the layout. Click on the icon to eliminate blank lines in the database. The icon will disable all the information in the layout. The icon selects the standard barcode font and displays the information using a fixed default font. The database may be setup in any format that conforms to a standard address. Database fields may be combined on a particular line and punctuation and spaces may be added. When finished click OK. NOTE: The database Field may be edited at any time by double clicking on it. To add a fixed return address to the media double click on the first line in the return address. The following window will appear. Type the information as shown in that window. Each line that uses a different type or style of type is entered by means of an Text Filed Editor window. When you have completed the entry below click OK. 18

The next step is to enter the rest of the return address. Double click on the second line in the return address area in the layout and enter the following in the Text Field Editor Field 3 window: Once you click the OK button, the second line will appear as you typed it in the Layout Editor window. To the right of the media layout is a vertical line, you can drag this line to the position where you want the information from the two edits to line up and then right click on the line. The lines will then line up with each other. The AstroJet Software has the flexibility to allow you to add additional information to your layout in any position on it. For the purpose of this tutorial, we will add the following line at the bottom of the layout: 19

You may add as many messages to the layout in any position on the media by simply enabling an Address Line in the Text Field Properties window and dragging the line from the blotter area to the position you would like to have it appear on the media. Then double click on the line and enter the information in the Text Field Editor window. The Logo icon is used to add logos and graphics in.bmp format to your design. When you click on the Logo icon or access it from the Fields drop box, under Logos, the Layout Editor-Logo Properties window appears. You may add up to eight logos to the layout. Each logo is selected by first activating one of the Logo Enable buttons and then typing in the file name and location. You can also click on the folder icon and browse for the desired file. The default is the logo folder located in the AstroJet software. Use this folder to store logos. The AstroJet is a 600-dpi printer. When creating graphics or logos for use on the AstroJet, 1 is equal to 600 pixels. A logo or graphics that is 300 pixels tall will print the width of a single print head or 1/2 high. If you wish to print a logo or graphic that would span two or more banked printheads it has to be taller than 300 pixels. Once you have found the logo you wish to use, click OK. The screen will return to the Layout Editor and the logo will appear in the lower right hand corner to the right of the media layout in the blotter area. Use your mouse to place the 20

logo or graphic on the layout as illustrated. The logo can be edited with Windows paint by double clicking on it. Press this button to add the USPS bar code to the address. Press the number 1 Enable button and then select the Field where the bar code is located in the database. Then press OK. The bar code will appear in the lower right hand corner of your screen just below the layout in the blotter area. Click and drag the bar code to its position under the address as shown. IMPORTANT NOTE: The bar code displayed in the Layout Editor view is a representation of the positioning of the bar code on your layout. If you use the data base view function in the Layout Editor, the bar code will appear the same for each record. When the record is printed on the AstroJet Printer the bar code will be the correct one for each zip code in the database. You may also add a barcode with the Layout Editor. This is used when the barcode appears as a five plus four in one data field and a separate two-digit delivery point in another field. Click on the Text Field Properties icon and Enable a font. Click OK. Drag the field to a position under or over the address and double click on it. When the Text Field Editor window opens, click on the barcode icon to select the Astro USPS font. Then select the fields that contain the barcode information from the drop down box and combine them on the same line without any spaces. Click OK and position the resulting image on the layout. The image will appear as follows: ~FIELD_4~ ~FIELD_5~ When in database view the actual barcode for each address will display. The actual database records can be viewed by clicking on the Template/Database View icon. A set of arrow buttons will appear below the icons that will permit you to step through the records or search for specific records.. Saving the Template Now that you have designed the template using the layout editor, it is time to save it. Click on File and select either Save Template or Save Template As and the Save As window will appear. You must give the template file a unique name with the extension.ajpjt then click Save. The Template will be saved in the AstroJet Data Projects folder. 21

Saving the Job IMPORTANT: Before exiting the Layout Editor you must create a job so that the data base and the layout can be output on your printer. To do this select, File and then select New Job. The Layout Wizard Select Print Range window will appear. Click Next>> to select Database View (database name). At this point, it is possible to select a specific range of records to be output. To set the range select the starting record that you wish to use by using the database advance buttons. Click on the left ( É) to choose the starting record. Use the same buttons to step to the last record you wish to print and click on the right button (É ) to set the end of the job. Selection of specific records to print can be done anytime by following this procedure. Always save the job to make the range changes permanent. If you wish to print all of the database records then skip this step and click on Next>>. The Save As window will appear. The default is the layout file name is displayed. Click save to save it or enter a unique name for the job with the.ajjob extension and click Save. The template and the job that have been created are now ready to be printed. Close the layout window by clicking File and then Exit. Running the Job Before running the job make sure that the AstroJet Printer is turned on and properly connected to the computer. There are two ways that a job can be selected to be run. One is from the AstroJet Control Panel button in the Layout Editor. icon on the desktop of the computer. The other is from the AstroJet Control Panel For the purpose of this tutorial, double click on the AstroJet Control Panel icon on the desktop. The following window will appear: 22

By clicking on the Open Folder icon, the Load Job window will open. Choose the job you just created and then click Load Job. The database information will now display in the Control Panel. The arrows below the database information can be used to step through the data. In addition, a Search, Search next, and Jump buttons are available to help you find a specific record 23

in the database. Simply click on the search or jump button and fill in the requested information. The following is a list and description of each search variable: Variable Default Description Search For Must be filled in. This field specifies the criteria the search must find. It can be a complete or partial, word or phrase. If it is Case Sensitive, check the box in the Options and make sure that the Search For is precise. If the criteria are in a specific field in the database it can be specified in the Look In box. Case Sensitive 0 Specifies whether upper and lower case characters should be treated as identical in searches. Non-zero value specifies searches are sensitive to the case of letters. 0 calls for case insensitive searches. Search direction All 0 Specifies a search the entire database. Non-zero value forces searches of the entire database in the forward direction, proceeding from the first record to the last. A 0 value in the Limit causes a directional search from the current position base on Search Forward, and Search Limit. Search Direction Forward 0 Specifies the direction of the search, either forward or backward. A number in Limit specifies forward searches, 0 specifies backward. Not used when Search All is set to a nonzero value. Look In (All Fields) Specifies the field the search will look in to. The value string must be a valid field name for the database in use, or (All Fields). If the Look In value doesn t match a valid field name (All Fields) is used instead. Limit search to: 0 Specifies the maximum number of records to search. 0 is implied to mean the number of records from the current position to the end of the database in the specified direction. Not used Search All is set to a non-zero value. Template The last search template specified. This is the default pattern to be searched for. NOTE: The icon is used to search for the next record. The arrow in the icon shows the direction that the search is moving through the database. When the last record is found that meets the criteria in the search the Control Panel Search window will reappear. 24

A description of the Control Panel controls follows: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1. Name of the Job file. 11. This button will print one piece for setup. 2. Current database record. 12. This button will open the Layout Editor. 3. These buttons and the ones to the right are 13. This area shows the status of the download used to step through the database. process. 4. Search is used to find a record that contains 14. The number of the current record is displayed specific information. here. 5. Continue searching for the same specific 15. The number of records in the printer buffer is information. displayed here. 6. Jump to a specific record by number. 16. The total number of records in the current database is displayed here. 7. The is used to open the job file to be used. 17. The status of the printer is displayed here. 8. The verifies the integrity of the database. 18. This is the number of the first record in the database selected for printing. 9. STOP will pause the printing process 19. This is the number of the last record in the database selected for printing. 10. GO is used to start printing the job 20. These buttons control the resolution of the printed image. 25

NOTE: When the job is running the display in the lower right hand corner of the Control Panel will tell you the speed of the printer in Inches Per Second (ips) and the approximate number of pieces being processed per hour. This only displays when the Printer is connected and printing pieces. Bundle and Bag Breaks A Bundle and a Bag Break feature are available in the AstroJet Control Panel Software. This feature will permit you to stop the AstroJet printer in order to separate the pieces according to USPS regulations. The various mail management software available for presorting have the ability to prepare your database to conform to Post Office regulations. We will not go into this part of the presorting, but we do suggest that you become familiar with the software you are using to presort your database. The USPS provides a wealth of information on their presorting regulations. Some of these are: 1. Domestic Mail Manual (DMM), published by the USPS and available by subscription by calling (202) 783-3238. 2. Postal Bulletin which provides corrections and additions to the DMM on a regular basis. You can subscribe to this by calling (202) 512-1800. 3. There are also several informative, free booklets available from your local Post Office and the USPS on the subject of preparation of presorted mail. 4. Much useful information can also be obtained from the USPS web site at www.usps.com. The bundle and bag break windows can be found under the Advanced button on the Control Panel. When you click on this button the Control Panel Advanced Settings window will appear. At the bottom of the window there are two buttons, Bag Break and Bundle Break. The functions of these buttons are similar. They are provided to permit you to separate bags of mail and bundles in the same job. You can use either or both of these to separate the pieces. To use this feature you must first put a non-alpha or numeric character in your database, either in one of the existing fields or create a field for the character. You may use any character except the tilde (~). All presorting software is capable of preparing your database in this way. For example we used (*) for bag break and (##) for bundle break. 26

Once you have loaded your job in the control panel, select Advanced, then select Bag Break, the above window will appear. You can enable these functions by clicking on the Enable Breaks to select it. Select the field where the break character was placed in the database. If you used a character other than the (*) place that in the Break Sequence block, then select pieces for the break in the Break Delay block. The printer will stop at the break. Then click OK. If you require a Bundle Break repeat the above sequence, but use a different character or field to designate this function. Remember you can not use any alpha or numeric character or the tilde (~) for this function. Start the printing process by clicking the GO button. When the AstroJet Control Panel software reaches a break character the printer will stop feeding. To restart the printing process press SELECT on the control panel. Running a Job Setting up the Feeder The following steps will assist you in setting the feeder portion of the AstroJet 2000: 1. Place one piece of media on the feeder table. Move the side guides out to their extreme open position. Release the separator-locking lever located on the left side of the feeder and raise the separators to their up and locked position. 2. There are four separators on the feeder. Use the two center separators for narrow media and the two end separators for wide media. Place the media under the separators and lower the separators so that they rest on the media. NOTE: Two types of separator tips are packaged with the AstroJet 2000. The set that is installed on the unit was designed for all types of media from single sheets of paper to booklets and carries the part number 90-103-09S. The second set is made from a harder material and can be used for all media except single sheets of paper. It has a part number of 90-103-09, 3. Move the locking lever up to lock the separators. 4. Adjust the side guides to the width of the media and set the back guide so that it just touches the back of the media. 5. Turn the AstroJet 2000 on and then turn the medial thickness knob to set the initial print head height as follows: Starting Up the AstroJet 2000 Media Thickness Dial Setting.004 to 1/32 0 to 2 1/32 to 1/16 2 to 3 1/16 to 1/8 3 to 7 1/8 to 1/4 7 to 10 It is a good idea to Purge the printheads before beginning to run a job. This can be done from the AstroJet 2000 LCD Display Panel. Press STANDBY, then ON LINE to put the AstroJet 2000 in the menu mode. Then using the NEXT or PREVIOUS buttons scroll to 27

PURGE: then press the SELECT button. Allow the AstroJet 2000 to run a few pieces then press SELECT again to stop the purge. Check that the pattern run on the media is even, without any blank areas or white streaks. If the pattern is OK, then return the AstroJet to the standby mode by pressing the STANDBY button. Anytime the AstroJet 2000 sits idle for a while the purge routine should be run before running the job. Printing the Job Click on the GO button to begin the job. The AstroJet 2000 will begin by rendering the fonts and logos and storing them in the Fonts folder. Depending on the complexity of the page this process takes only a few minutes. Once a font or logo is rendered, the AstroJet 2000 can call it up from this folder for reuse the next time a job that uses that particular type or type style is run. Monitoring the Job The AstroJet 2000 can be stopped by pressing the SELECT/PRINT key or by clicking on STOP in the Control Panel software without affecting the job. The printer will resume printing at exactly the same point when it is back on-line. NOTE: THE ASTROJET 2000 MUST BE OFF-LINE FOR THE FOLLOWING SETTINGS TO BE CHANGED. Checking the Piece Counter To check the number of pieces run proceed as follows: 1. Turn the printer off-line. 2. Use the PREVIOUS or NEXT key to bring COUNTERS to the top line. 3. Press the SELECT key, the asterisk will disappear and MACH CYCLES with a number will appear. 4. To reset this to 0 turn the machine off and then on. 5. To continue press the SELECT the asterisks will reappear. Setting Print Resolution To set or change the Print Speed: 1. Turn the Printer off-line. 2. Use the PREVIOUS or NEXT button to bring PRINT SPEED to the top line in the display. 3. Press the SELECT key, the asterisk will disappear. 4. Use the PREVIOUS or NEXT key to select the desired speed LOW, MEDIUM, or HIGH. NOTE: If Standard resolution is selected there will be two speed choices available STD and HIGH. If Draft resolution is selected three speed choices will be available: LOW, STD, and HIGH. In the HIGH-resolution mode only the LOW speed is available. 5. Press the SELECT key to lock in the selection. The asterisk will reappear. 28

Purge the Printheads It is necessary to Purge the printheads, especially when the AstroJet 2000 has been idle for a period of time: 1. Turn the printer off-line. 2. Load media into the feeder on the AstroJet 2000. 3. Use the PREVIOUS or NEXT key to bring PURGE to the top line of the display. 4. Press the SELECT key. The asterisk will disappear and the AstroJet 2000 will start to feed media and purge the print heads. 5. Press SELECT again to stop the purge and return the AstroJet 2000 to STAND BY. 6. Check that there is a consistent pattern printed on the media. If not, repeat Step 4 and 5 until the pattern is consistent. Setting Left Margin To increase the gap at the lead edge of the piece: 1. Turn the printer off-line. 2. Use the PREVIOUS or NEXT key to bring LEFT MARGIN to the top line. 3. Press the SELECT key. The asterisk will disappear. 4. Use the PREVIOUS or NEXT key to select the desired left margin in 0.1-inch increments. 5. Press the SELECT key to lock in the selection. The asterisk will reappear. Printing Tips Types of Media The AstroJet 2000 will print on many types of mailing media, but some restrictions apply. As with any other printing process, the texture of the media has a direct effect on both the print quality and the ink drying time. It is best to test each new type of media to determine performance levels before beginning the Job. Since coated and plastic types of paper do not easily absorb ink, smearing may occur. Print may appear fuzzy on very porous paper. Another cause of fuzzy printouts is excessive buildup of dust within the machine, or a printhead is too far away from the media. Be aware, that when printing in the High Quality mode, drying time for the ink is longer than in the other modes. In addition, when humidity is high, drying time is increased. Media Thickness The AstroJet 2000 will handle pieces up to 1/4 thick (0.250 ). All folds must be crisp and even. 29

CAUTION DO NOT use stapled pieces in the AstroJet 2000. DO NOT use paper- clipped pieces in the AstroJet 2000. These methods of binding the mail piece will damage the printheads, affect print quality, and may seriously damage your printer. The Astro Warranty Policy will not cover components damaged through improper use. The USPS does not accept this type of mail for its automated equipment. Databases The AstroJet 2000 System is capable of handling many types of databases. There are, however, some limitations. To avoid problems we offer the following suggestions to help you improve the operation of your AstroJet 2000 System. Large ODBC Databases Random accessed ODBC databases are not indexed on the first column. As a result the performance of the printer may get slower and even stop when using very large databases. To prevent this from occurring, the following actions can be taken before the database is loaded into the AstroJet 2000 software: 1. The user can convert the ODBC database to a text database (*.CSV file) with the Layout Editor, and then subsequently open the project with that alternate database. The Layout Editor explicitly indexes text databases, so performance is not an issue for these files. Note: the Layout Editor retains ODBC field names in the first record of the *.CSV file, so when you select it later, you should check off that the first record contains field names. 2. The ODBC database vendor should be encouraged to index their database (on the first column ascending). The index may be packaged as part of the database file, or as a separate index file depending on the format of the database. 3. The users can index the database themselves. To do this, you will need a database management program for the database type you have. For example to index an Access database (*.mdb files) require Microsoft Access, and to index dbase III, IV and V (*.dbf) use Microsoft FoxPro. 4. Use sufficiently small ODBC databases that this effect doesn t affect printing. If the database has been saved in the ODBC format there are additional safeguards that have been added to the layout Editor and Control Panel to warn you and offer a means of changing the database and improving the performance of the system. The following solutions have been programmed into the AstroJet 2000 software: 1. The Layout Wizard generates a warning when an ODBC database has been selected. There is no way for the Layout Editor to determine if the database is 30

indexed, so the user is warned of the potential consequences of selecting an ODBC database. 2. The ODBC to CSV converter was added to the Layout Editor, so users have a viable alternative to using ODBC databases directly. 3. A timer has been placed in the Control Panel that monitors ODBC reads. When reading of a record exceeds a threshold, the Control Panel stops the job with a timeout error. Converting ODBC Databases to *.CSV (Comma Separated Value Format) To convert an ODBC database to a Comma Separated Value file, use the following procedure: 1. Create a new project, or open an existing project in the Layout Editor that uses the ODBC database you wish to convert. For purposes of this discussion, the example will be MY SAMPLE.DBF. 2. From the File menu select Convert Database. 3. A wizard is started which tells you the conversion is about to occur, and that it may take awhile. It also tells you the converted database will be stored in your databases folder, under the current name with.csv tacked on the end. In example the output would be MY SAMPLE.DBF.CSV. 4. Press Next to start the conversion, or Cancel to quit. If you start the conversion, you will not be able to interrupt it the process will continue until the conversion is complete. 5. Exit and restart the Layout Editor. From the Startup Wizard select Modify an existing project with a replacement database. Work through the wizard and select the converted database, in this case MY SAMPLE.DBF.CSV. 6. You can ignore the warning about database structure, because in this case the structure will be identical. 7. The wizard will ask about # of fields per record leave it at 0, is the First record is used to record field names check this box, and delimiter information leave the defaults. Press Next or Finish. Your project is now associated with the converted database. Access to any record in the database should be almost instantaneous and the Control Panel should always provide individual page information faster than the printer can supply stock. Indexing a Microsoft Access *.MDB file To index an Access database file for use with the Layout Editor and Control Panel you will need Microsoft Access 97 (or 2000). This should be installed on the target system to ensure the same leave of ODBC is available to Access and the Layout Editor and Control Panel. Then follow this procedure: 1. Start ACCESS and open the database file, (for example: MY SAMPLE.MDB. 2. Select the table to be used - here it is MY SAMPLE. 31

3. Click the Design button. A window displaying the characteristics of each field (column) in the database is drawn. 4. Select the first row by clicking in the blank gray square to its left. This selects the characteristics of first column. 5. At the bottom left click in the cell to the right of the heading Allow Zero Length to display a drop down arrow, from which you will select yes. 6. Click the cell to the right of the heading Indexed to display a drop down arrow, from which you select Yes (Duplicates OK) 7. Exit Access. Indexing a dbase III, IV, V, FoxPro (*.DBF) File To index a dbase file for use with the Layout Editor and Control Panel you will need Microsoft FoxPro. This should be installed on the target system to ensure the same leave of ODBC is available to Access and the Layout Editor and Control Panel. Then follow this procedure: 1. Start FoxPro and open the database file, (for example: SAMPLE.DBF. 2. Select the table to be used - here it is SAMPLE. 3. If you are asked about the character set to use, select 1252 Windows ANSI. 4. From the View menu select Table Designer. A tabbed dialog wills popup. 5. Select the Fields tab. Note the name of the first field. Select the Indexes tab. 6. In the cell under Name, type the name for your index. In this case SAMPLE. 7. Once this is entered other fields become available. Fill in the following fields: A. Order click to show an up arrow (ascending) B. Type select regular C. Expression enter the field name you noted above D. Filter leave blank 8. Click Okay and Yes to make structures permanent. 9. Exit FoxPro. 32

Section 5 Maintenance This section shows you how to care for and replace inkjet cartridges, clear paper jams, and perform routine operator maintenance to the AstroJet 2000 Printer. Other problems such as not printing, poor print quality, etc., are also covered. Special tips and suggestions to help you increase efficiency and avoid problems are also included. The Inkjet Cartridge The AstroJet 2000 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 51645A Inkjet cartridges based on three lines of 20 characters at 10-point size per address is: High Quality Standard Quality Draft Quality NOTE: These figures can vary depending on the font selected. To Replace the HP 51645A Inkjet Cartridge: 50,000 addresses 100,000 addresses 200,000 addresses 1. Remove the cartridge by pulling the top toward you until the cartridge is free from the retaining latch. Lift the cartridge up and out of the holder. 2. Remove a new print 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. 3. With the gold printhead pointing toward the rear of the unit, slide the bottom edge of the cartridge down along the front of the bracket until it slides partly into place. 4. Press the upper part of the cartridge toward the bracket until it clicks into place under the retaining clip of the bracket. 5. Repeat this procedure for each cartridge. 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. Storage Short-term storage is defined as less than 2 days or less than 1 day in a hot and dry environment. Long-term storage is defined as more than 2 days or more than 1 day in a hot and dry environment. 33

Disposal Short-term Storage Leave the cartridge in the AstroJet 2000 for short periods of time, 2 days or less. The next time that the AstroJet 2000 is used, the printhead may have to be cleaned per the cleaning instructions, below. Long-term Storage HP 51645A Cleaning the Printhead Keep the printhead in an area that is relatively free of dust and paper particles that is not too dry 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 will need to be cleaned. The cartridge may be disposed of in normal manner. If there should be an ink spill, use soap and water to clean up any problem areas. Abrasive soap also works well to get the ink off of hands. In order to achieve good print output; maintenance of the printhead is required. Paper fibers and dust can build up on the printhead degrading the print quality. Proper printhead maintenance will allow the cartridge to produce good print quality its whole life. A cotton Tex Wipe and distilled water is one of the best ways to wipe ink and other build-up off of the printhead. A Tex Wipe is 100% cotton, high-density cloth with no chemical additives. Something comparable is adequate to wipe the nozzles. A good choice of wipe would have the following qualities: Soft Fiberless No chemical additives Moist with distilled water A cloth should NOT be: Abrasive Dry Made of small fibers that can be left behind on the cartridge s nozzle plate Never use the following to wipe the printhead: Industrial paper towels these cloths usually contain a high recycle content and are abrasive 34

Toilet paper this is usually not fiberless Sponge particles from the sponge can be left behind on the nozzle plate The cloth must be soft so that it does not scratch the printhead. It should be fiberless because small fibers on the cloth can be left behind and block the nozzles of the cartridge. The cloth must be moist or it will scratch the printhead. Scratches on the printhead prevent the ink from coming out of the nozzle straight. If the ink drops do not come out of the nozzles straight they will not land on the paper in the proper place causing fuzzy text. Distilled water is better than tap water because tap water contains an unmonitored amount of minerals. During wiping, the water cleans out the nozzles and the firing chambers. A small amount of water mixes with the ink in the chambers. Over time, the minerals in tap water can leave behind deposits in the chambers that block it completely. A blocked chamber will show up as a white streak in text or graphics. The direction and force of the wipe is also important to note. During wiping, harmful particles on the top of the printhead can be wiped into the nozzles if you are not careful. The cartridges need to be wiped in a certain way to obtain optimal print quality. It is important to wipe the cartridge nozzles in the direction of the nozzle rows for optimum print quality. See below: HP 51645A Purging the Nozzles If the 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 will then show up in the printed text or graphic. In order to obtain better print quality, this ink plugs need to be forced out or purged. A Purge routine is built into the AstroJet 2000 Printer. It can be accessed from the LCD panel on the AstroJet 2000 Printer. Refer to Section 4 Operating the AstroJet 2000, under Running a Job; Purge the Printheads. 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 AstroJet 2000 Printer LCD Display panel. 3. Wipe the printhead again with a moist cloth. 35

NOTE: For more information refer to the Troubleshooting Print Heads in Section 6 Trouble Shooting Guide. Jams in the AstroJet 2000 Printer If a jam occurs, TURN THE ASTROJET 2000 OFF LINE. The missed addresses can be recovered at the computer from the control panel by stepping back to the place in the job where the jam occurred. No data will be lost. Some possible reasons for jamming are: 1. Multiple pieces of media pass at once. 2. Damaged media, such a dog-eared (turn 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 2000. 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 print heads. All pieces of the jammed media must be removed from the feed path. 2. Use the control panel in the AstroJet 2000 Software to recover any lost addresses. 3. Restart the job by putting the AstroJet 2000 back ON LINE and resume printing by using the GO button on the AstroJet 2000 Software Control Panel. Cleaning WARNING THE ASTROJET 2000 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! The AstroJet 2000 must be regularly cleaned 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 AstroJet 2000, unplug it from the power receptacle and remove the covers. Refer to the parts manual for this. The internal areas are 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. The exterior of the machine may be cleaned with any standard household cleaner which is non-abrasive and does not contain plastic harming solvents. 36

CAUTION Never spray or pour cleaners directly on or into the AstroJet 2000 Printer. Excess liquid could harm electronic parts. Always dampen a rag with the cleaner and apply it to the parts to be cleaned. 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. 37

Notes 38

Section 6 Trouble Shooting Guide The following trouble shooting guides are provided to assist you in solving any problems that might occur with the AstroJet 2000 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 trouble shoot any problem. Inkjet Cartridges HP 51645A Print Cartridges CONDITION PROBLEM SOLUTION 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 Re-insert the cartridge into the carriage Wet wipe and purge the cartridge (There are clogged nozzles.) Clean interconnects Insert a new Print Cartridge Black streaks around text Wet Wipe the cartridge (There is ink buildup). 39

AstroJet 2000 Printer PROBLEM REASON REMEDY No communication Improper output (address information out of order, misfeeding, etc.) Improper cabling Unit not receiving power Wrong interface settings Static electricity Dirty media sensor Use Proper cable (see Sect. 3) Check plug connections, on/off switch and fuse on back panel (see Sect. 2) Check software or data base on PC Turn AstroJet 2000 of and on Clean media sensor Extra lines; losing data Data base problem Check data in data base program Not printing on media Media not positioned properly 1. Adjust print band vertically 2. Adjust media margin setting on AstroJet 2000 Print too light or missing character dots Media jams Clogged or dirty printheads Running out of ink Double feeding Media is curled or bent Media is too thin Either purge or clean cartridges Replace inkjet cartridges Adjust feeder Uncurl media Media must be at least 0.008 WARNING DO NOT REMOVE THE SIDE COVERS OF THE ASTROJET 2000 PRINTER THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS! 40

AstroJet 2000 Software ERROR MESSAGE PROBLEM SOLUTION Template File is Corrupt Job Loading Failure Template View Warning New Fields missing from layout screen The AstroJet 2000 Control Panel can not open the related.ajpjt file. A problem arises loading the job file. Due to the design of the database management software, it is not possible to display records simultaneously in the Layout Editor and Control Panel. Fields not visible in blotter area on Layout Screen. Re-open AstroJet 2000 Layout Editor and attempt to open the file. Re-save the file and attempt to open the AstroJet 2000 Control Panel again. If the file still will not open in the AstroJet 2000 Layout editor, restart the computer and try again. Try a backup or older copy of the.ajpjt file Click on Remove Job, if you know the file is out of date and no longer in use. Click on Recreate Job to reopen the Layout Editor, then click on the File Menu and select New Job, select the print range and Click on Next>> to continue. Click Next>> again and then save the job with a new name. Click on Cancel to return to the Control Panel and select another job file. When you click OK the Layout Editor will switch automatically to the Template View. Caution: If an attempt is made to switch to Database View in the Layout Editor, a fatal error will occur and any unsaved information will be lost. The line may be piled up on top of each other. Click and drag the first line into the appropriate Printhead Area. Open the Address Field property sheet by right clicking on one of the existing address lines or by selecting Address from the Fields Menu. Select OK. The fields should re-appear in the blotter area. 41

Software continued ERROR MESSAGE PROBLEM SOLUTION New Fields missing from layout screen. Continued Printing in Wrong Location on the mailing piece Fields not visible in blotter area on Layout Screen. Printing too far to the Left or Right. Printing Too High or Low Right click on one of the fields that has already been positioned and click OK on the field property sheet an they should re-appear Right click on one of the fields that has already been positioned and click OK on the field property sheet an they should re-appear Make sure that the size of the mailing piece entered in the Setup Menu is correct. Make sure that the piece on the Layout Screen looks EXACTLY the way you want your piece to look. Use the rulers to verify that the fields are located the proper number of inches form the edges. Adjust the left margin setting. Check the product detection sensor to verify that it is properly aligned. Check image on layout screen. Adjust the paper guide, or individual printheads on their mounting brackets to adjust how far from the bottom edge of a piece the fields are printed. 42

Appendices APPENDIX A ASTROJET 2000 Specifications The information (electrical and physical dimensions, etc.) on the AstroJet 2000 is presented here for your reference. Specifications are subject to change without notice. PRINT QUALITY (Dots Per Inch) PRINT SPEED (Inches Per Second) High Quality Standard Quality Draft Quality High Quality Standard Quality Draft Quality 600 x 600 dpi 600 x 300 dpi 600 x 150 dpi 20 ips 35 ips 60 ips IMAGE AREA Total of 2 1/2 inches using five printheads MEDIA SIZES Maximum 17 long x 13 1/2 wide up to 1/4 thick Minimum 5 long x 3 wide up to 1/4 thick PRINT MECHANISM NUMBER OF CARTRIDGES INKJET CARTRIDGE LIFE (approximate) GRAPHICS AND LOGOS HP 51645A Inkjet Cartridge 5 cartridges Addressing: High Quality 1,050,000 characters Standard Quality 2,100,000 characters Draft Quality 4,200,000 characters (five line address labels only, logos and other printing not included in the above) Allows printing of Bitmapped graphics, logos, and pictures SOFTWARE AND FONTS Windows 98 All Windows True-Type fonts PRINT COLORS INK OPERATOR DISPLAY OPTIONS (LCD) PC INTERFACE DIMENSIONS ELECTRICAL WEIGHT Black, Fast Drying Black, Yellow, Red, Green, Blue Water based requiring drying assistance for coated stock Counter, Print Resolution, Purge, Left Margin, BIOS Version Centronics Parallel Cable 17 H x 26 L x 21 W 120 VAC, 60 Hz @ 0.75 Amps 76 lbs. (34.6 kg.) 43

APPENDIX B - Supplies and Optional Hardware The following supply items and optional hardware are available from your Astro Machine Distributor: Supplies Black Inkjet Cartridge Fast Drying Black Inkjet Cartridge Yellow Inkjet Cartridge Red Inkjet Cartridge Green Inkjet Cartridge Blue Inkjet Cartridge HP 51645A HP 6195A HPC6173A HPC6168A HPC6169A HPC6170A Optional Hardware Various Conveyors Available 44

ASTROJET 2000 PARTS CATALOG 45

Group 1 - Covers 46

KEY# PART NO DESCRIPTION QTY 1. 21-100-14 COVER, R/H 1 2. 21-100-20 P/H COVER WELDMENT & DECAL 1 3. 21-100-19 CLOSURE, REAR 1 4. 21-100-18 COVER, L/H 1 5. 21-100-26 COVER WELD, L/H 1 6. 21-108-01 COVER, TOP ASSY. 1 7. 97-100-65 CABLE BRACKET 1 8. 123-0928 SCREW, 4-40 1/2 PH BIND HD 2 9. 123-1323 SCREW, TRUSS HD 4-40 X 3/16 SS 8 10. 123-1158 SCREW, 4-40 X 3/16 UNDRCT SS 8 11. 123-0017 SCREW, 10-32 X 1/4 PH TRUSS HD 2 12. 21-108-08 SPACER 2 13. 123-0390 KNOB, SPEED CONTROL 1 14. 123-0612 SCREW, 6-32 X 1/4 PAN HD 6 15. 80-120-25 SPRING, JOGGER ROD 2 Group 1 Covers 47

48 Group 2 Mechanical

KEY# PART NO DESCRIPTION QTY KEY# PART NO DESCRIPTION QTY 1. 21-100-05 FRAME, L/H SIDE 1 42. 21-130-06 ARM ASSY., R/H 1 2. 21-500-04 POWER INLET-GROUND 1 43. 21-132-01 ASSY., INTERMEDIATE ROLLER 1 3. 21-100-37 BRACKET, MOTOR 1 44. 21-130-08 BELT, CONVEYOR ENDLESS 10 4. 123-1332 TIMING BELT 40DP 250 GR 5/16" KEVLAR 1 45. 123-1331 TIMING BELT 40DP 75 GR 3/16" KEVLAR 2 5. 21-149-12 SHAFT, ECCENTRIC 2 46. 94-109-03 PULLEY, 26 GR 1 6. 94-123-15 PULLEY, 34 GROOVES 2 47. 123-0994 PULLEY, 40 DP 1 7. 21-100-29 BRACKET 2 48. 21-131-02 ASSY., DRIVE ROLLER 1 8. 94-124-14 ECCENTRIC CAM 4 49. 21-115-00 ASSY., PULL OUT ROLLER 1 9. 94-124-08 ECCENTRIC BLOCK SUB-ASSY. 4 50. 21-114-00 ASSY., FRONT FEED SHAFT 1 10. 123-1175 SCREW, SET 10-32x5/8 W/INSERT 4 51. 123-0873 BELT, 160XL037 BLACK 1 11. 123-0050 NUT, 10-32x5/16 HEX ZINC 4 52. 94-105-04 PULLEY ASSY., 16 GROOVES 1 12. 123-0701 SCREW, 10-32x3/16 PH TRUSS HD 4 53. 63-105-15 WASHER,.505ID,.703OD,.030THICK 1 13. 123-0275 SCREW, 6-32x1/4 OVAL CSK PH ZINC 28 54. 123-0934 BELT, 90XL037 BLACK NEOPRENE 2 14. 90-103-52 ASSY., BALL BEARING 14 55. 21-113-00 ASSY., MIDDLE FEED SHAFT 1 15. 123-0017 SCREW, 10-32x1/4 PH TRUSS HD 23 56. 21-113-03 ASSY, PULLEY 17 GR 1 16. 21-100-11 COVER, INSIDE 2 57. 123-0277 BELT, TIMING 110XL031U 1 17. 21-100-04 FRAME, R/H SIDE 1 58. 123-0573 BELT, 130XL043 BLACK 1 18. 123-0494 SCREW, 10-32x1/4 BTN HD SOC CAP 2 59. 21-111-00 ASSY., CLUTCH SHAFT 1 19. 123-0461 SCREW, 6-32x3/16 PH RND HD ZINC 13 60. 65-300-43 STUD, BRAKE 1 20. 123-1323 SCREW, TRUSS HD 4-40x3/16 SS 9 61. 123-0081 C-CLIP #5133-25 1 21. 123-0620 FOOT, RUBBER 4 62. 123-1340 SCREW, TRUSS HD 4-40x1/8 SS 1 22. 123-0612 SCREW, 6-32x1/4 PAN HD 16 63. 65-303-01 MOTOR PULLEY, 14 GROOVES ASSY. 1 23. 21-149-08 BAR, CROSS 1 64. 123-0298 SCREW, SET 10-24x3/16 SOC PT 1 24. 21-149-05 COVER, SENSOR 1 65. 21-112-00 ASSY., REAR FEED SHAFT 1 25. 123-1023 SCREW, 4-40x5/16 PANHEAD PH 6 66. 123-0064 WASHER, LOCK 1/4 MED SPLIT 7 26. 21-133-13 ENCODER BRACKET, WELDMENT 1 67. 123-0524 SCREW, 1/4-20x1/2 SOC CAP 7 27. 123-1135 SCREW, 6-32 X 1/4 PH TRUSS HD SS 4 68. 123-0063 WASHER, 1/4" PLAIN MOTOR & PUMP ZINC 3 28. 123-0127 SCREW, 6-32x1/8 PH PAN HD 2 69. 123-0706 PIN, DRIVE LOCK - 3/16x1/2 2 29. 123-0446 SCREW, 8-32x5/16 PH UNDRCUT SS 2 70. 21-500-14 ENCODER ASSY. 1 30. 21-100-06 BASE, MOTOR 1 71. 123-1111 PIN, GROOVE 5/32 x 3/8 4 31. 21-100-25 CLOSURE 1 72. 123-0036 ROLL PIN, 3/32 X 5/8 STEEL 1 32. 21-100-43 BRACKET, SENSOR 1 73. 123-0137 TIMING BELT, 70XL031 1 33. 123-1204 SCREW, 6-32x1/4 BTN HD SOC CAP 4 74. 123-0567A WASHER, 5/16 IDx.7ODx1/16 THICK ZINC 1 34. 123-0674 SCREW, 6-32x1/4 SOC HD BLK OXIDE 4 75. 21-112-05 PULLEY ASSY., 14 GR 1 35. 21-103-01 BELT SIDE GUIDE ASSY. 1 76. 71-122-06 PULLEY, 12XL GROOVES 1 36. 21-130-05 ARM ASSY., R/H 1 77. 21-116-00 MOTOR BRACKET ASSY. 1 37. 21-130-03 SUPPORT, BELT 1 78. 56-101-02 RUBBER FEED ROLLER ASSY. 8 38. 21-130-01 CENTER PLATE (SMALL) 1 79. 90-102-21 FEED ROLLER ASSY. 4 39. 123-0675 SCREW, 6-32x3/16 PH FH UNDRCUT SS 2 80. 90-102-21B FEED ROLLER ASSY. 4 40. 21-130-04 COVER 1 81. 123-0322 SCREW, SET 8-32 X 1/4 8 41. 21-133-01 ASSY., EXIT ROLLER 1 * ONLY FOR FIRST 20 UNITS Group 2 Mechanical 49

Group 3 Feed Table 50

KEY# PART NO DESCRIPTION QTY 1. 21-100-07 CENTER PLATE WLED. 1 2. 21-100-32 SLIDER 1 3. 21-100-31 SLIDER 1 4. 123-1335 CURVED DISC SPRING GR1074 HC 1 5. 123-0148 STEEL WASHER, 7/16 OD X.200 ID X 1/32 1 6. 123-0004 SCREW, 10-32 X 5/8 SOC HD 1 7. 21-100-33 SUPPORT, PAPER 1 8. 123-0002 SCREW, 10-32 X 3/8 PH UNDRCUT 2 9. 123-1205 SS SCREW, 8-32 X 1/4 BTN HD SOC 3 10. 94-102-05 SIDE GUIDE BLOCK SUBASSY. 2 11. 123-0126 SCREW, 8-32 X 1/4 PH MS SS 4 12. 21-124-08 UNDRCT SIDE GUIDE L/H 1 13. 21-124-07 SIDE GUIDE R/H 1 14. 65-302-10 SUPPORT 1 15. 21-121-01 ASSY, METERING PLATE (SEE 1 16. 21-122-01 GUIDE, ARM ASSY. 1 17. 123-0612 SCREW, 6-32 X 1/4 PAN HD 6 Group 3 Feed Table 51

Group 4 Metering Plate 52

KEY# PART NO DESCRIPTION QTY 1. 123-0185 SCREW, 10-32 X 3/8 SOC CAP 4 2. 66-101-09 SPACER 4 3. 123-0461 SCREW, 6-32 X 3/16 PH RND HD ZINC 3 4. 123-0121 DISC SPRING, HIGH CARBON STEEL 4 5. 123-0127 SCREW, 6-32 X 1/8 PH PAN HD 4 6. 21-121-03 HOLDER, MTRN'G 2 7. 123-0347 BALL, STTEL.187 D 4 8. 123-0017 SCREW, 10-32 X 1/4 PH TRUSS HD 1 9. 21-121-02 PLATE, MTRN'G. 1 10. 123-1310 SCREW, 6 X 3/8 PH FLAT SELF TAPPING TYPE A 18-8 SS 4 11. 21-121-12 MTRN'G FINGER 4 12. 123-0096 WASHER, PLASTIC 3/8 X 3/4 X1/16 4 13. 66-101-10 STUD 4 14. 66-101-07 STUD 1 15. 66-101-04 BAR, MTRN'G. BRK'T. RELEASE 1 16. 123-0327 ROLL PIN, 3/23 X 7/16 1 17. 66-101-05 LEVER 1 18. 123-0169 C-CLIP 1/4 (Crescent) 1 19. 21-101-15 KNOB, MTEN'G. 4 20. 90-103-09 SEGMENT, MTRN'G (Hard) 4 90-103-09S SEGMENT, MTRN'G (Soft) 4 21. 66-101-13 WASHER, PLASTIC 3/8 X 3/4 X1/16 4 22. 123-0751 SCREW, 6-32 X 3/8 PH UNDRCT SS 4 23. 66-101-14 STAND OFF 3 24. 21-121-08 COVER, MTRN'G. PLATE 1 25. 123-0675 SCREW, 6-32 X 3/16 PH FH UNDRCUT SS 3 Group 4 Metering Plate 53

Group 5 - Electrical 54

KEY # PART NO DESCRIPTION QTY KEY # PART NO DESCRIPTION QTY 1. 21-100-22 COVER, R/H 1 32. 21-100-05 FRAME, L/H SIDE 1 2. 94-100-24 BRK'T., PCB MOUNTING 1 33. 123-0612 SCREW, 6-32x1/4 PAN HD 14 3. 94-100-10 CONTROL PANEL PRINTER REV.2 1 34. 21-100-30 STUD, PCB 4 4. 21-500-05 WIRE HARNESS 1 35. 123-0566 SCREW, 6-32x1/4 PH FH UNDRCT 6 5. 21-500-06 WIRE HARNESS 1 36. 95-100-32 STANDOFF 4 6. 21-100-19 CLOSURE, REAR 1 37. 21-500-22 WIRE HARNESS, EXTENSION FOR AJ-2000 1 7. 21-500-12 MOTOR ASSY. 1 38. 21-500-17 WIRE HARNESS, EXTENSION FOR AJ-2000 1 8. 21-500-16 WIRE HARNESS 1 39. 94-500-07 SERVO MOTOR ASSY. 1 9. 21-500-07 WIRE HARNESS 1 40. 21-500-09 POTENTIOMETER ASSY 1 10. 123-1075 SPEED CONTROL 1 41. 21-500-11 SENSOR ASSY., MEDIA 1 11. AD409 CABLE, CONTROL PANEL 1 42. 21-100-43 BRK'T., SENSOR 1 12. 123-1313 POWER SUPPLY 1 43. 123-0096 WASHER, PLASTIC 3/8x3/4x1/16 2 13. 123-0018 ROLL PIN 1/8 x 3/4 - BLACK 1 44. 123-0086 NUT, 3/8-32x1/2x3/32 HEX SS 1 14. 21-100-37 BRK'T., MOTOR 1 45. 123-0390 KNOB, SPEED CONTROL 1 15. 94-500-18 WIRE HARNESS, INTERFACE 1 46. 123-0085 LOCK WASHER, INTERNAL TOOTH 3/8 SS 1 16. 123-1104 CIRCUIT BREAKER 1 47. 94-116-01 MOTOR BRACKET 1 17. 21-500-02 WIRE HARNESS, POWER INLET GRND 1 48. 21-500-10 POTENTIOMETER ASSY 1 18. 21-500-03 WIRE HARNESS, POWER INLET NEUTRAL 1 49. 21-100-04 FRAME, R/H SIDE 1 19. 21-500-01 WIRE HARNESS, INLET MOD HOT 1 50. 21-100-49 BRK'T., FRONT CABLE 2 20. 21-500-04 POWER INLET GROUND 1 51. 97-100-48 CABLE SPRING 6 21. AD407 WIRE HARNESS, PWR SPLY CONTROLLER 1 52. 97-500-22 FLEXIBLE CABLE 5 22. 21-500-13 CLUTCH ASSY. FEED 1 53. 21-140-00 HEAD PLATFORM (5 CARTRIDGES) WITH HDS 1 23. 21-500-08 WIRE HARNESS PWR SUPPLY PWR BOARD 1 54. 123-1023 SCREW, 4-40x5/16 PANHEAD PH 1 24. 97-500-30 MOTOR CONTROL PC BOARD 1 55. 123-0113 TIES, PLASTIC 2 25. 123-0024 SCREW, 10-32x3/8 PH TRUSS HD MS 1 56. 123-0274 SCREW, 6-32 X 3/8 PH TRUSS HD 4 26. 123-0237 WASHER, STAR #10 EXTERNAL 3 57. 123-0192 NUT, HEX 6-32 ZINC 4 27. 21-500-15 INTERFACE CABLE 1 58. 123-0252 WASHER, STAR #6 EXTERNAL ZINC 4 28. 21-500-20 WIRE HARNESS, CENTRONICS CABLE 1 59. 21-201-00 SINGLE CARTRIDGE HEAD 1 1 29. 97-500-01 PRINT HEAD DRIVER PC BOARD (HP45) 3 60. 21-202-00 TWO CARTRIDGE HEAD 2,3 1 30. 21-500-00 PROCESSOR PC BOARD 1 61. 21-212-00 TWO CARTRIDGE HEAD 4,5 1 31. 21-500-14 ENCODER ASSY. 1 62. 123-0035 BEARING, NMB R-4HH 4 Group 5 Electrical 55

Notes 56

Copyright 2000 Astro Machine Corporation Elk Grove Village, Illinois 60007 05/31/2000