ASTRO AstroJet 1000 Inkjet Printer Installation, and Operating Manual
SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE ASTROJET 1000 SYSTEM. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: ü Keep hands, hair, and clothing clear of rollers and other moving parts. ü Avoid touching moving parts or materials while the machine is in use.
TABLE OF CONTENT Section 1 – Getting Acquainted 1 The AstroJet 1000 The Control Panel 1 3 Choose a Location Connecting the AstroJet 1000 Installing the Inkjet Cartridges Setting up the Feed Installing the Software on the Computer 5 5 6 6 7 Section 2 – Installing the AstroJet 1000 Section 3 – Software Tutorial 5 9 Using the AstroJet 1000 System Software Setting up the Job Saving the Template Saving the Job 9 13 18 18 The Computer Control Panel Running a Job Printer Settings Types of Media Databas
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Section 1 – Getting Acquainted ASTROJET 1000 The AstroJet 1000 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 20,000 postcard (3.5 X 5.5 inch) mail pieces per hour. 4 1 2 3 5 6 7 1 2 CONTROL PANEL – See page 3 3 SHEET SEPARATORS – There are four sheet separators that help separate the media as it is being fed.
1 5 2 3 4 1 PRINT HEAD COVER – Shown open for illustration purposes, but should be in the closed position for running. 2 PARALLEL PORT – The printer cable from your computer should be connected here. 3 MEDIA TRANSPORT BELTS – The media is transported under the printheads on these belts. 4 PRINTHEAD CARRIAGE – The AstroJet 1000 has four printheads. Head 1, 2, and 3 are banked together on the rail. Head 4 shares the same rail, but is opposite and independent of the other heads.
CONTROL PANEL 1 2 3 4 5 6 7 8 9 1 ONLINE – The indicator on this key lights when data is sent to the AstroJet 1000 and it is ready to begin printing. Turns the printer on and off line so that menu mode can be accessed. (See Printer Settings, page 26) 2 PREVIOUS – When the AstroJet 1000 is in the menu mode this key will scroll to the previous selection. When the selection is unlocked with the select key, this key will scroll through the selections available in the selected menu.
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Section 2 – Installing the AstroJet 1000 To install the AstroJet 1000 printer the following must be done: • Choose a location for the AstroJet 1000 Printer • Plug in the printer and connect it to the computer • Install the Inkjet Cartridges • Set up the feed on the printer • Install the AstroJet 1000 software on the computer • Create a job to be printed (refer to Section 4 – Software Tutorial) Choose a Location The AstroJet 1000 should be placed on a sturdy worktable or cabinet at least 12 inche
Install the Inkjet Cartridges The AstroJet 1000 can be configured with 4 inkjet cartridges. 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 a latch lever mounted on the inkjet cartridge holder. Release the lever by raising it vertical.
4. Adjust the side guides to within 1/32-inch of the media and set the back guide so that the media is raised approximately 1/2-inch and rests on the curve of the back guide. When running 10 inch or longer or heavy media you may have to set the back guide so that it just touches the back of the media. 5. Turn the AstroJet 1000 on and then turn the media thickness knob to set the initial print head height as follows: Media Thickness .
3. Install the CD in the computer. The CD should start automatically. If it does not click on the Start button, then select Run. Type “D:\Setup.exe” (where D is the CD drive) and then click OK. 4. The AstroJet Setup Menu will appear on your screen. It contains five options: Install Printer Software Read the Manuals Browse this CD Install Adobe Acrobat – This is version 4.0 of Adobe Acrobat for reading and printing the Operator Manuals. www.astromachine.
Section 3 – Software Tutorial This section assumes that the AstroJet 1000 software has been installed on the computer and that the computer is connected to the printer. Following the instructions below will teach you how to create a job, process that job, and in Section 4 send the job to the printer and print it. Additional information on the operation of the software can be found in the AstroJet Help file on your computer.
The “Layout Editor – Untitled” screen will appear. Click on the icon or File, then New and the “Layout Editor – Select Database” window will appear. Leave the box “Does this template require a database?” checked and click OK. The “Select Database” screen will now appear. Click on the drop down menu “Files of Type” and select “1 UP LABELS (*TXT)”. Highlight “4Lines.TXT” and click on Open to continue. The “4Lines.txt” database is included in the software and is indexed.
CSV databases are also indexed, but additional information about the character that delimits the fields is required for the software to create the index file. Click on the appropriate delimiter and then click OK. Microsoft Access *.MDB, dBase III, IV, V, and FoxPro *.DBF files are automatically converted to *.CSV files with a comma delimiter.
Layout Editor screen allows you to choose from a list of standard envelope sizes or permits you to create your own custom envelope size. If you choose to create a custom envelope size, select custom, enter the size of the piece in width and length, give the piece a name in the “Save As” window and click Save As then OK. The new size will be saved to the list as a Standard size for future use. When you click on OK, the “Layout Editor – Untitled” window will open.
By clicking on the RED numbers to the left of the layout you can move the print band positions on the layout. The drop down menu bar consists of the following items: File View Fields Setup Tools Help Each of these menus provides choices that perform the tasks required for setting up the job. The second line contains icons that represent the basic tasks required to set up the job. For the purpose of this tutorial, we will use both the icon buttons and the menu bar to set up a sample job.
When you click on this icon the Envelope Properties window will open. You may choose any of the standard envelope sizes listed under Standard or you may select Custom and create your own envelope size. To do this highlight the Width and type in the actual width of the media, and then highlight the Length and type in the length of the media. You may use any number or fraction from 3 inches up to 12 inches in width and from 5 inches up to 14 inches in length.
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. The box at the right of the window contains the names of the fields. Click on each field name to add it to the layout.
layout that does not use a database (see the end of this section for more information. The icon and the icon are used to select and display multiple field barcodes or barcodes in other formats than the standard USPS barcode. More information on using these two icons appears under the barcode section. In addition to the above this window is used to change the font type, font size, and type style such as Bold, Italic, Underlined, or Strikethrough.
You may add as many as 24 messages to the layout in any position on the media by simply enabling a text field in the “Layout Editor – Text Field Properties” window. Then drag the text field from the blotter area to the position you would like to have it appear on the media. Double click on the new field and modify it in the Text Field Editor window. The Logo icon is used to add logos and graphics in .BMP format to your design.
If the database contains more than one field for the barcode, or you wish to use a barcode other than the USPS barcode use the text editor to combine fields to get the proper barcode do the following: Click on the “Text Field Properties” button and the “Layout Editor – Text Field Properties” window will open. Enable a field and click OK. Drag the “Data Line” from the blotter area to the location you wish the Barcode to appear on the layout.
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. 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 or Save As… and the “Save As” window will appear. Give the template file a unique name then click Save.
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Section 4 – Running the Job THE COMPUTER CONTROL PANEL There are two ways that the Control Panel can be selected for running a job. One is from the AstroJet 1000 Control Panel button in the “Layout Editor”. The other is from the “AstroJet 1000 Control Panel” icon on the desktop of the computer. CAUTION: Always make sure that the AstroJet 1000 is connected to the computer and that it is turned on. If it is not the software can not establish communication with the printer.
1 2 3 4 5 6 Name of the Job file. 7 This area tells you about the job and the record being printed. AstroHP45 must display Ready in order to print. Current Database Record. For more information on Databases see page 29. Use this button to select the Job you wish to run. Pressing this button while a job is running will stop the printer. Pressing this button after a job is loaded will start the printing process. These buttons permit you to search through the database for a record.
Running a Job Setting up the Feeder The following steps will assist you in setting the feeder portion of the AstroJet 1000: 1. Release the separator-locking lever located on the operator’s side of the feeder and raise the separators to the up and locked position. Place one piece of media on the feeder table. Move the side guides out to their extreme open position. 2. There are four separators on the feeder. Use the two center separators for narrow media and all four separators for wide media.
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 1000 sits idle for a while the purge routine should be run before running the job. Printing a Test Print Make sure that the AstroJet 1000 printer is properly connected to the computer and turned ON. Open the “Control Panel” either from the desktop or from the icon in the layout editor.
5. Press the SELECT key to lock in the selection. The asterisk will reappear. 6. Press the STAND BY key to exit the Settings Menu and return the Printer to the print mode. Purge the Printheads It is necessary to Purge the printheads, especially when the AstroJet 1000 has been idle for a period of time: 1. With the AstroJet 1000 power switch ON, press the STAND BY key to put the printer On-line, then press the ON LINE key to enter the Settings Menu. 2. Load media into the feeder on the AstroJet 1000.
1. With the AstroJet 1000 power switch ON, press the STAND BY key to put the printer On-line, then press the ON LINE key to enter the Settings Menu. 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 “MEDIUM” and “LOW”.
Databases The AstroJet 1000 System is capable of handling many types of databases including .TXT, .CSV, Microsoft Access. MDB, and dBase III, IV, V, FoxPro (*.DBF). TXT and CSV files are handled as they are. The rest of the database files are converted automatically by the AstroJet Software to CSV files. In addition whenever you update a file the AstroJet Software will reconvert and re-index it if you place the updated files in the AstroJet Database folder in the software.
Advanced Features Clicking on the Properties… button permits you to enter the “Control Panel – Properties” window. With this window you can control functions such a updating the printer BIOS, align the printheads, set a time delay in the feeding to increase stock drying time, and enable the bag and bundle break feature. The following discusses these features. Update Bios From time to time as improvements or changes in operating systems occur it may be necessary to update the Printer’s BIOS.
The Bundle and Bag Break control windows can be found under the Properties… button on the Control Panel. When you click on this button the “Control Panel – Properties” window will appear. At the top of the window there are two tabs, Bag Breaks and Bundle Breaks. Their functions are similar. They 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.
There is an optional feature on the Control Panel of the Printer that permits you to disable the break function. See the section on “Printer Settings” for more information. Feeder Settings In order to permit enough time or space between pieces to assist in drying the ink or to help the operator to handle the piece more efficiently. The Feeder Settings… button is provided. When you click on it the following screen appears. Click on “Should Feeder Delays be enabled?” to activate the feature.
2. The printheads are initially locked with the others in the same Band. They should be unlocked using the Unlock button. 3. Each index mark on the Alignment Controls represents 4 thousandths of and inch. You can adjust the print heads to half that value, to within 2 thousandth for a total of 20 thousandths of an inch to either side of the factory setting. 4. Simply drag the alignment pointer on a print head to a new setting to change the exact location at which it starts to print.
If you open the control panel while the printer is turned off the Control Panel software will ask you if you want to disable the printer for this session. This is the same as checking the box.
Section 5 – Maintenance This section discussed how to care for the inkjet cartridges, clear paper jams, replace sheet separators, and perform routine operator maintenance to the AstroJet 1000 Printer. The Inkjet Cartridge The AstroJet 1000 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.
Short-term Storage Leave the cartridge in the AstroJet 1000 for short periods of time, 1 day or less. The next time that the AstroJet 1000 is used, the printhead may have to be cleaned and purged Long-term Storage 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.
order to obtain better print quality, these ink plugs need to be forced out or purged. A Purge routine is built into the AstroJet 1000 Printer. It can be accessed from the LCD panel on the AstroJet 1000 Printer. Refer to Section 4 – Operating the AstroJet 1000, 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.
Cleaning The AstroJet 1000 WARNING THE ASTROJET 1000 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 1000 must be cleaned regularly of accumulated paper dust and ink. Depending on the types of media that are run, paper dust may accumulate within the printer and on the transport.
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 1000 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.
AstroJet 1000 Printer PROBLEM Printer does not turn on REASON No power to printer REMEDY Check that power cord is plugged in Check that power outlet is live Check fuse on power switch No communication Improper output (address information out of order, misfeeding, etc.) Improper cabling Use Proper cable (see Sect. 2) Unit not receiving power Check plug connections, on/off switch and fuse on back panel (see Sect.
AstroJet 1000 Software ERROR MESSAGE Template File is Corrupt PROBLEM The AstroJet 1000 Control Panel can not open the related ajpjt file. SOLUTION Re-open AstroJet 1000 Layout Editor and attempt to open the file. Re-save the file and attempt to open the AstroJet 1000 Control Panel again. If the file still will not open in the AstroJet 1000 Layout editor, restart the computer and try again. Try a backup or older copy of the .ajpjt file Job Loading Failure A problem arises loading the job file.
Software continued… ERROR MESSAGE PROBLEM SOLUTION New Fields missing from layout screen. Continued… Fields not visible in blotter area on Layout Screen. 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 reappear Printing in Wrong Location on the mailing piece Printing too far to the Left or Right.
Appendices APPENDIX A – ASTROJET 1000 Specifications The information (electrical and physical dimensions, etc.) on the AstroJet 1000 is presented here for your reference. Specifications are subject to change without notice.
Computer Requirements 1. An IBM or Compatible Pentium 100 Megahertz PC or better. 2. Windows 95, 98, 2000 or NT installed. 3. A minimum of 10 Megabytes of free hard disk space. 4. At least 16 Megabytes of RAM. (32 Megabytes for Windows 2000 and NT) 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.
APPENDIX B - Supplies and Optional Hardware The following supply items and optional hardware are available from your Astro Machine Distributor: Supplies Black Inkjet Cartridge HP 51645A Fast Drying Black Inkjet Cartridge HP 6195A Yellow Inkjet Cartridge HPC6173A Red Inkjet Cartridge HPC6168A Green Inkjet Cartridge HPC6169A Blue Inkjet Cartridge HPC6170A Versatile Black HPC8842A Optional Hardware Various Conveyors Available 43
APPENDIX C – Software Options Full 256 ASCII Character Set for AstroJet Printer The AstroJet 1000 software uses the basic 128-character set to print the addresses. This speeds up downloading of the fonts and is more efficient. In some cases it may be necessary to use the entire 256 ASCII character set to print the addresses. European addresses that use accent marks over certain letters for example.
Sometimes it is necessary due to the media layout or to obtain the most efficient feeding of the material that the media be turned around. When this is done the address must be printed in reverse so that it appears right side up on the finished piece. This is referred to as Reverse printing. The AstroJet Printer accomplishes this in the software by reversing the address. While the direction of the media through the printer remains the same, the printing changes as in the illustration to the right.
Printing without a Database It is possible to print return addresses on envelopes, logos, and other information on media without a database. One application would be to put the return address on the flap of an envelope. To do this select a the New Template icon or New… from File menu and when the Layout Editor – Select Database window appears deselect the “Does this template require a database?” Then click OK. The “Layout Editor – Stock Properties” window will open.
Notice that in the lower information line the Database says N/A meaning that no database is attached to this layout. Continue with the layout by clicking on the Text Field Properties icon and activating a font. Click OK and “Data line1” will appear in the blotter area. Click on this and drag it to the place that you wish the information to appear on the layout, just as you would with a database field.
When you have completed the layout it should look like the one below: Save the template and then create a job by clicking on File and then New Job… to save the job. Next turn on the printer and click on the Control Panel icon. The control panel will open, then click on the to load the job. You will note that no data will be shown in the “Current Database” window in the control panel. When you click GO, the “Control Panel – Number of Copies” window will open.
Special Insert Characters for Text Fields Built in to the “Text Field Editor” are several special characters that can be used to increase the information on your layout.
Adding Instructions to the Operator It is possible for an operator to change information on a mailing piece before it is printed without using the Layout Editor. A situation where the same basic mailing list and layout is used each month but some special message is changed would be one example. In the sample below the piece used in the tutorial is modified so that a special message can be added when the mail list is run each month.
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Copyright © 2001 Astro Machine Corporation Elk Grove Village, Illinois 60007 06/30/2001
