ASTROJET 2600P/2650P/2800P PRINTER SERVICE MANUAL Astro Machine Corp. 630 Lively Blvd. Elk Grove Village, IL 60007 Phone: (847) 364-6363 Fax: (847) 364-9898 www.astromachine.
SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE ASTROJET 2600P/2650P/2800P PRINTER. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: 9 Keep hands, hair, and clothing clear of rollers and other moving parts. 9 Avoid touching moving parts or materials while the machine is in use.
TABLE OF CONTENTS Table of Contents SECTION 1 – Installation Unpacking the AstroJet 2600P/2650P/2800P Attach the Side Guides to the Printer Choose a Location Connecting the AstroJet 2600P/2650P/2800P Installing the Ink Cartridges Setting up the Feed Installing the Printer Driver Installing the BIOS Manager SECTION 2 – Trouble Shooting 1 1 1 1 1 2 3 3 4 7 Power Problems Interface Communication Problems LCD Display Problems Feeding Problems Printing Problems Print Placement Problems Print Content Incorre
TABLE OF CONTENTS Main Processor PC Board Replacing Printheads and Transport Belts Replacing Drive Motor, Motor Control PCB, Power Supply SECTION 6 – Maintenance The Inkjet Cartridge Cleaning Appendices Appendix A – AstroJet 2600P/2650P/2800P Specifications Appendix B – Supplies and Optional Hardware Appendix C – Wiring Diagram ii 37 37 41 43 43 45 47 47 48 49
SECTION 1 INSTALLATION Section 1 - Installation Unpacking the AstroJet 2600P/2650P/2800P Tools required Standard #2 Phillips head screwdriver. 1. Remove accessories from feed area of printer. 2. Remove foam blocks from printhead area. Attach the Side Guides to the Printer 1. Remove the two screws from the side guide blocks. 2. Position the side guide screw holes so that they align with the holes in the side guide blocks. 3.
SECTION 1 INSTALLATION Connecting to the Computer Plug the parallel printer cable from your computer into the rear of the printer and latch the two locking clips. The cable used to connect the AstroJet 2600P/2650P/2800P to the computer must not exceed 6 feet long. Install the Inkjet Cartridges The AstroJet 2600P/2650P/2800P can be configured with up to six inkjet cartridges.
SECTION 1 INSTALLATION Setting up the Feed 1. Release the separator-locking lever located on the operator’s side of the feeder, raise the separators to the up, and locked position. Move the side guides out to their extreme open position. Place one piece of media in the center of the feed table. 2. There are four separators on the feeder. Use the two center separators for narrow media and all four separators for wide media.
SECTION 1 INSTALLATION NOTE: These are initial settings. It may be necessary to adjust the MEDIA THICKNESS control to optimize the print quality 8. Press the ONLINE key, and then press the ENTER key, to test feed media. Installing the Printer Driver A dedicated printer driver is included with the Printer. It is installed on your computer and is used by your applications whenever you are printing from the Printer.
SECTION 1 INSTALLATION Using the BIOS manager From time to time, you may receive new BIOS for the AstroJet 2600P/2650P/2800P printer. When the new BIOS is received, it will have to be loaded in the flash ROM on the printer. This is where the BIOS manager comes in. First, you will receive the new BIOS either via e-mail or on a floppy disk. It will have to be loaded into the BIOS manager software. 1. Open Windows Explorer and click on Program Files, then PCL Only Printer Utilities.
SECTION 1 INSTALLATION Notes 6
SECTION 2 TROUBLE SHOOTING Section 2 – Trouble Shooting This section is arranged by first the condition that might occur, and then by possible problems, their cause and recommended solutions. Power Problems CONDITION PROBLEM SOLUTION Power is on, nothing happens. No power to printer Check that the power cord is plugged in. Check that the power outlet is live. Check the fuse in the main power switch. Replace with a fuse of the same rating. Check the fuses on the power supply PC Board.
SECTION 2 TROUBLE SHOOTING CONDITION PROBLEM LCD shows solid line of characters or garbage. Power supply. LCD displays solid black line or lines Static electricity Bad power supply No firmware (BIOS) Bad processor PC Board SOLUTION Check voltages and inspect the power supply connections to the processor PC Board. Turn printer off and then on.
SECTION 2 TROUBLE SHOOTING CONDITION Jams continued PROBLEM Worn separator tip. Printhead adjusted too low. Conveyor tape(s) under printhead broken. SOLUTION Replace separator tip. Raise printhead Replace tapes. Printing Problems CONDITION PROBLEM No printing: Media is blank after going under printheads. Sensor did not see the piece and send the signal to print to the PC Board.
SECTION 2 TROUBLE SHOOTING CONDITION White lines/streaks in a line of print Smeared ink PROBLEM Ink cartridge nozzle dirty Cartridge not properly inserted Cartridge was hit, shaken, or dropped Tap water was used to clean cartridge and mineral deposits have blocked the ink chamber Wrongly directed or forceful wiping have driven particles into nozzles Cartridge low on ink Tape covering print nozzle or vent holes Printhead connections not set Bad printhead drive card Carriage too low Coated paper preventing
SECTION 2 TROUBLE SHOOTING CONDITION Address too close to center of media Address printing partially off media PROBLEM Chosen media size in layout is too small The physical location of the printheads do not match the layout Feed ramp not set properly Chosen media size in layout is too large The physical location of the printheads do not match the layout Feed ramp not set properly SOLUTION Set correct media width size in layout Check image on layout screen, Adjust paper guide or printhead Adjust feed ram
SECTION 2 TROUBLE SHOOTING NOTE: Remove all media from the printer before performing these tests. To access the Test Print mode press and hold the TEST PRINT key until “Service Menu” is displayed on the printer control panel. You can use the + or – key to step through the test options. Drive Speed Test Press the ENTER key to start the main drive motor and display the belt speed in inches per second. Press the ENTER key to stop the main drive motor.
SECTION 3 FUNCTIONAL OPERATION Section 3 – Functional Operation Sequence of Operation The user prepares the printer 1. Selects number and color of print cartridges required and installs cartridges in proper location. 2. Uses a single piece of media to set sheet separators. 3. Loads media and adjusts side guides to within 1/32” of media. 4. Stacks media in feeder and adjusts feed ramp. 5. User adjusts Media Thickness knob for proper printhead contact with media. 6. Turns printer on.
SECTION 3 FUNCTIONAL OPERATION Printing The print engine consists of six stationary printheads and moving transport belts, which position the media. Four circuit boards control the printer. (See the end of this chapter for their description and location. Printer Functional Description 1.
SECTION 3 FUNCTIONAL OPERATION Printer Control Panel When you first turn the printer ON, the light in the TEST PRINT key lights and the display becomes active. At this point, the printer is ready to print if it is connected to your computer. The printer control panel keys can be used to access various functions that help the operator control the printer. These functions and their operation are as follows: ENTER key The ENTER key is used to start the printer printing under production situations.
SECTION 3 FUNCTIONAL OPERATION Pressing the ENTER key will turn this function ON or OFF. The function will remain as changed until the operator changes it again. Turning the printer ON and OFF will not affect the setting. NOTE: The Print Enhancement feature will time out after 100 seconds if no media is going through the printer. Once media is being printed it will restart. Installing New Printheads – The printer is capable of telling you when a printhead is running low of ink.
SECTION 3 FUNCTIONAL OPERATION 2600P printer has six printheads arrange in one, two, two and one sequence. The 2650P has six printheads arranged three and three and the AstroJet 2800P has eight printheads. The printer driver describes to the printer how to print your job. It controls the operation of the printer and allows you to send fixed and variable text and graphics to the printer. Within your data, management software is a print function. In that, print function is a properties button.
SECTION 3 FUNCTIONAL OPERATION Features Tab The Features Tab/ Advanced Options depending on the operating system is used to change the speed and resolution of the Printer, to add a delay to the feed to provide separation between the pieces, and to print and overlay with the job. The first feature is the Print Quality, which has two settings. One for the Resolution of the print quality and the second for the appropriate speed. Changing the resolution to a higher number e.g.
SECTION 3 FUNCTIONAL OPERATION To use the Overlay feature, first create a layout in an application such as Microsoft Word. Place all of the fixed information and graphics on this layout. Open the layout and go to Print in the File menu. Click on Features and then click on Overlay. Select “Contains overlay” from the box, and then click on Apply and OK. Next, click OK on the “Print” window. The overlay will down load and the printer will start running.
SECTION 3 FUNCTIONAL OPERATION The rest of the settings on this tab should be left as they are. Paper size is always “Max Print Area” and Orentation is always “Portrait”. Do not change them. Printing from Microsoft Word If you are not using a specific program designed for mailing applications it is possible to print your mail pieces using Microsoft Word. This section will cover how to layout a piece and to print from Microsoft Word. To begin open a new page and turn on the tool bar for Mail Merge.
SECTION 3 FUNCTIONAL OPERATION The next step is to create a text box so that you can position the address the proper distance from the lead edge of the piece. Once the page layout is set, you might want to save it as a template for use later. When you have completed the steps above the layout for an AstroJet 2600P should look like the one below.
SECTION 3 FUNCTIONAL OPERATION choose “Printer”, the merge will send directly to the printer and each record will be printed. The next selection is “Records to be merged”. You can select All or From. The last selection is “When merging records”. The default is “Don’t print blank lines when data fields are empty.” This should be left checked. Clicking on Merge will start the process of merging the documents.
SECTION 4 ADJUSTMENTS SECTION 4 – Adjustments WARNING The electrical adjustments are made with the machine under power. Make sure to use non-metallic tools when adjusting potentiometers on PC Boards.
SECTION 4 ADJUSTMENTS AstroJet 2600P/2650P/2800P Carriage Assembly Timing Adjustment REQUIREMENT: To ensure the carriage assembly lowers smoothly and contacts the media evenly on all corners. ADJUSTMENT: 1. 2. 3. 4. 5. 24 Unplug the machine, remove the front, and rear covers. (5 screws each) Turn the MEDIA THICKNESS knob to “0”. Remove gear from potentiometer two hex screws [1].
SECTION 4 ADJUSTMENTS ASTROJET 2600P/2650P/2800P Drive Belt Tension Adjustment REQUIREMENT: To ensure the drive belt has the proper tension. ADJUSTMENT: 1. 2. 3. 4. 5. Unplug the machine and remove the Operator side cover. (5 screws) Loosen the four screws [1] that mount the main drive motor to the frame. Move the motor up or down to obtain at least a 1/8” deflection in the belt. Tighten the four screws [1]. Replace the side cover.
SECTION 4 ADJUSTMENTS AstroJet 2600P/2650P/2800P Output Voltage Adjustment REQUIREMENT: To provide proper output from power supply to machine. ADJUSTMENT: 2. 1. Remove the left-hand rear cover and connect voltmeter probe to GND [1] and TP3 [2] on Interface PC Board P/N 97-500-30. Turn the printer ON. INTERFACE PC BOARD 26 3. Adjust R14 (V1 ADJ) potentiometer [3] on the Power Supply module P/N 123-1313 to obtain 14 VDC ± 0.1 V.
SECTION 4 ADJUSTMENTS AstroJet 2600P/2650P/2800P Media Sensor Adjustment REQUIREMENT: To assure that the media sensor senses the media. ADJUSTMENT: 1. Remove the left-hand rear cover and connect voltmeter probe to GND [1] and TP4 [2] on the Interface PC Board P/N 97-500-30. 2. Insert a BLACK media card over the sensor. Turn the printer ON. 3. Adjust R20 potentiometer [3] to read 0.5 VDC maximum. 4. Apply lacquer such as nail polish to the potentiometer to prevent movement of the adjustment. 5.
SECTION 4 ADJUSTMENTS AstroJet 2600P/2650P/2800P Print Speed Adjustment REQUIREMENT: To provide the proper speed of the printer at each of the print quality settings. ADJUSTMENT: 1. With the printer connected to the computer, remove the left-hand, right-hand rear covers, and the rear panel. Turn the printer ON. 2. Set the potentiometers R1 [1], R7 [2], R11 [3] and R14 [4] on the Interface PC Board, to their center or middle positions. 3.
SECTION 4 ADJUSTMENTS ASTROJET 2600P/2650P/2800P Brake Adjustment REQUIREMENT: To provide the proper tension on the feed shaft brake assembly for proper feeding of the media. ADJUSTMENT: 1. Disconnect the Printer from the power source. 2. Remove the Operator side cover, Non-Operator side cover and rear cover. 3. Reconnect the printer to the power source and turn it ON. 4. Turn the brake tension adjusting screw [1] clockwise until the brake exerts a drag on the feed rollers. 5.
SECTION 4 ADJUSTMENTS Notes 30
SECTION 5 DISASSEMBLY – ASSEMBLY SECTION 5 – Disassembly/Assembly Disassembly – Assembly Procedures Tools Required #2 Phillips head screwdriver 3/32” Allen wrench #1 Phillips head screwdriver 5/32” Allen wrench Basic Disassembly Turn off Power Disconnect Power Cord Disconnect Interface Cable 31
SECTION 5 DISASSEMBLY – ASSEMBLY Removing the Side Guides Remove four screws as shown at right. Removing the Feed Ramp Remove two screws as shown at right. This part does not have to be removed in order to remove the feed deck. Removing the Print Cartridges 1. Lift the blue lever. 2. Remove the cartridge. 3. Close the lever.
SECTION 5 DISASSEMBLY – ASSEMBLY Replacing the Separator Tips. 1. Before replacing the separator tips, unplug the AstroJet 2600P/2650P/2800P. 2. Release the sheet separator-locking lever on the left side of the feeder. 3. Push down the black tab on the separator to expose the screw. 4. Use a Phillips screwdriver and remove the screw holding the metal cover over the separator. Use the tip of the screwdriver to pry the separator tip out of its holder. 5.
SECTION 5 DISASSEMBLY – ASSEMBLY 3. Remove the feed roller access plate. 4. Rotate the feed roller shaft so that the screws are face up and use a 3/32-inch Allen wrench to remove the two button head cap screws. This will permit you to remove one half of the feed roller. Rotate the shaft until the two screws holding the second half of the feed roller in place are accessible. Remove those screws also. Install the feed roller half and replace the screws.
SECTION 5 DISASSEMBLY – ASSEMBLY Service Disassembly Procedures NOTE: The following disassembly should only be done by a qualified, trained service representative. CAUTION: When touching electronic boards wear a wrist strap that is grounded. OPERATOR SIDE COVERS 1. Remove the three screws at the top of the left hand operator side covers. Then remove the two screws from the bottom of the cover. 2. Remove the cover. Do not pull it too far away as the cable to the control panel could be damaged. 3.
SECTION 5 DISASSEMBLY – ASSEMBLY NON-OPERATOR SIDE COVERS 1. Remove the two screws at the top of the left hand nonoperator side cover. Then remove the two screws from the bottom of the cover. 2. Remove the cover. 3. Remove the two screws at the top of the right hand non-operator side cover. Then remove the two screws from the bottom of the cover. The Interface PC Board [A] is under this cover. NOTE: The AstroJet 2600P is shown. The same procedure is used for the AstroJet 2800P 4. Remove the cover.
SECTION 5 DISASSEMBLY – ASSEMBLY MAIN PROCESSOR PC BOARD – 2600P 1. PARALLEL PORT 2. USB PORT 3. ENCODER 4. PRINTER DRIVER PC BOARDS 5. POWER INPUT 6. OPERATOR CONTROL PANEL 7. INTERFACE PC BOARD CONNECTOR MAIN PROCESSOR PC BOARD 2800P 1. POWER INPUT 2. ENCODER 3. INTERFACE PC BOARD CONNECTOR 4. OPERATOR PANEL 5. PARALLEL PORT 6. PRINTER DRIVER PC BOARDS 7.
SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING PRINTHEADS AND TRANSPORT BELTS 1. Remove both the Operator and Non-Operator side covers and the Main Processor PC Board. 2. Remove top cover by removing the two screws that attach it to the frame and the two springs. 3. Remove cover over printhead assembly by removing the two Allen screws front and rear. 4. Remove the ribbon cable from each cartridge. Take care to prevent damage to the ribbon cable or the connectors. 5.
SECTION 5 DISASSEMBLY – ASSEMBLY 8. Continue disassembly by removing the ground screw and ground wire from the carriage assembly. 9. Then remove the two screws [4] that attach the carriage support bracket on the non-operator side. 10. Continue the disassembly by removing the mounting bracket on the operator side by removing the three screws [5]. You may find it necessary to remove the shield around the print head assembly by removing the four screws [6], also. 11.
SECTION 5 DISASSEMBLY – ASSEMBLY 12. Remove the two screws [7] on the non-operator side and on the operator’s side. Remove the front cover. 13. Refer to Step 12 and remove the two screws [8] on the non-operator’s and the operator’s side and remove the belt guide assembly. 14. Continue the disassembly by removing the six screws [9] Step 12, from the bearing caps on each side of the machine and remove the bearing caps.
SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING DRIVE MOTOR, MOTOR CONTROL PCB AND CLUTCH 1. Remove operator right hand cover and non-operator left hand cover. 2. Remove the four screws [A], two each side from the rear cover plate and remove the rear cover plate. 3. Unplug the motor from the motor speed control and then, remove the four Allen screws [B] that attach it to the operator side-frame. Remove the drive belt, and then remove the motor from the machine. 4.
SECTION 5 DISASSEMBLY – ASSEMBLY Notes 42
MAINTENANCE Section 6 - Maintenance This section covers how to care for the ink cartridges, clear paper jams, replace the sheet separators, and perform routing maintenance on the printer. The Inkjet Cartridge The inkjet cartridges must be replaced when out of ink, when print quality is poor, or when purging and cleaning have not helped the image quality.
MAINTENANCE 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. Short-term Storage Leave the cartridge in the Printer for short periods of time, 1 day or less.
MAINTENANCE Purging the Nozzles If the printhead sits inactive for a period, ink may dry in the nozzles. Printing may not remove these “ink plugs” from the nozzles. White streaks will then show up in the printed text or graphic. In order to obtain better print quality, these ink plugs need to be forced out or purged. A Purge routine is built into the AstroJet 2600P/2650P/2800P Printer. It can be accessed from the LCD panel on the Printer from the MENU key.
MAINTENANCE Notes 46
APPENDIX A Appendix A – AstroJet 2600P/2650P/2800P Specifications PRINT TECHNOLOGY ADDRESS SPEED PRINT QUALITY (Dots Per Inch) IMAGE AREA PRINT ORIENTATION INK MONITOR FONTS PRINTS MATERIAL SIZE MATERIAL THICKNESS FEEDER CAPACITY: MEMORY PRINT COLORS INK SOFTWARE DIAGNOSTICS FIRMWARE UPDATE PC INTERFACE COUNTERS DUTY CYCLE DIMENSIONS WEIGHT ELECTRICAL OPTIONS AJ 2600P Inkjet, 6 HP 51645A High Capacity Inkjet Cartridges AJ 2800P Inkjet, 8 HP 51645A High Capacity Inkjet Cartridges 26,000/hr - #10 Envelopes
APPENDIX B Appendix B – Supplies and Optional Hardware The following supply items and optional hardware are available from your Astro Machine Dealer: 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 Conveyor / Stacker Available Drop Tray 48
Copyright © 2007 Astro Machine Corp. Elk Grove Village, IL 60007 02/27/2007 Part Number: 300-AJ2600P/2650P/2800PSRM Rev.
