Astro Machine Astrojet 2 User manual

ASTRO MACHINE CORP.
Astrojet II
High-Speed In-Line Inkjet Printer
Installation and Operating Manual

Table of Contents
Section
Section 1 - Introduction....................................................................................1
Section 2 - Getting Acquainted.......................................................................2
Components................................................................................................................2
Operator Display Screen and Menu...........................................................................6
Section 3 - Installation and Setup...................................................................8
Choosing a Location...................................................................................................8
Installing the Inkjet Cartridges....................................................................................9
Plugging in the Astrojet II............................................................................................9
Setting up the Astrojet II............................................................................................10
Section 4 - Operating the Astrojet II.............................................................12
Starting Up.................................................................................................................12
Preparing a Job.........................................................................................................12
Running a Job...........................................................................................................15
Printing Tips...............................................................................................................16
Section 5 - Operator Maintenance................................................................18
Replacing the Inkjet Cartridges................................................................................18
Jams..........................................................................................................................20
Troubleshooting Table..............................................................................................21
Cleaning.....................................................................................................................22
Section 6 - Appendices..................................................................................23
Specifications............................................................................................................23
Setting up the Computer...........................................................................................24
Optional Hardware and Software.............................................................................26
Electrical Parts Layout..............................................................................................29
Mechanical Parts Layout ..........................................................................................30
Wiring Diagram..........................................................................................................31

Section 1
Astrojet II High-Speed In-Line Inkjet Printer Introduction
1
Section 1 - Introduction
This Section, Introduction, describes how this manual is arranged.
Section 2, Getting Acquainted introduces the Astrojet II and describes major controls,
indicators, and important areas with which the user or operator should be familiar.
Section 3, Installation and Setup describes and illustrates how to install and get the
Astrojet II ready for printing. This procedure is usually a one-time requirement.
Section 4, Operating the Astrojet II describes and illustrates how to set up and get the
Astrojet II to run a particular addressing job.
Section 5, Operator Maintenance shows how to replace inkjet cartridges, and how paper
jams may be quickly and safely cleared. Other problems such as no printing, poor print
quality, etc., are also covered. Included in this section are special tips and suggestions that
will help you increase efficiency and avoid problems.
The Appendix is where important but infrequently used information is presented. The
Appendices are arranged as follows:
Appendix A, Specifications, lists the more important Astrojet II characteristics,
e.g., electrical, physical, etc.
Appendix B, Setting Up Your Computer, provides some general information on
setting up either your personal or mainframe computer so that it is compatible with
the Astrojet II.
Appendix C, Optional Hardware and Software, as its name implies, presents a
brief list of other equipment which may be used to further enhance the operation of
the Astrojet II. They are available as options.

Section 2
Astrojet II High-Speed In-Line Inkjet Printer Getting Acquainted
2
Section 2 - Getting Acquainted
The Astrojet II is a high-speed in-line inkjet printer capable of printing addresses, and if required, bar
codes up to 20,000 mail pieces per hour. Before getting into the operation of the Astrojet II, there is
some basic information necessary for its efficient and problem-free use.
To understand and operate the Astrojet II better, let's look at its two main areas.
1. Components
2. Operator Display Screen And Menu
Components
The main areas of the Astrojet II are shown in the following drawing.
These areas are described in the following paragraphs.
Power Switch
Power Cord Receptacle Centronics
Parallel Port
Interface
Socket
Fuse
Figure 1

Section 2
Astrojet II High-Speed In-Line Inkjet Printer Getting Acquainted
3
Transport
The media to be addressed rides on the transport belts. The transport has adjustable side guides and
belts that adjust to differently-sized media.
Printer
The printer is the most important area of the Astrojet II. It is here that addresses are printed on the
media. Two important features of the printer that you should become familiar with are:
•The Control Panel
•The Media 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 II.
The Media Thickness Adjustment
The Envelope Thickness Adjustment is to the left and on the side cover of the ON-LINE button. It
adjusts for media thickness and is turned counter-clockwise for thin media, clockwise for thick media.
Control Panel
Media Thickness
Adjustment
Figure 2

Section 2
Astrojet II High-Speed In-Line Inkjet Printer Getting Acquainted
4
Keypad Definitions
CONTROL OR INDICATOR DESCRIPTION
OPERATOR DISPLAY
ON-LINE
PREVIOUS
NEXT
SELECT
TEST
RESET
STANDBY
Indicates Astrojet II status including menus and error
messages. (Any display readout indicates that unit is ON).
When this indicator key is lit, the Astrojet II is ready to accept
address data from your computer and begin printing. Turns
the printer on and off-line.
When in the menu, will scroll to the previous selection.
When in the menu, will scroll to the next selection.
Locks and unlocks selection when in the menu. When
pressed while the printer is on-line, the printer will feed, but
will not print.
Will print a test pattern.
Will reset the counter and put the count into memory.
Will put the printer back on-line after timing out.

Section 2
Astrojet II High-Speed In-Line Inkjet Printer Getting Acquainted
5
Interface and Power Panel
While facing the control panel of the Astrojet II, the interface panel can be found at the rear of the
machine. It contains an outlet for an interface cable for an output conveyor and a Centronics parallel
port. From the same perspective, the power panel can be found at the left side of the Astrojet II. It
contains the main power switch and power-cord receptacle. The font card slot is located above the
control panel.
The printer has several devices that you need to know about. The internal components are shown in
the following drawing.
Power Switch
Power-cord
Receptacle
Figure 3
Centronics
Parallel Port Interface
Socket
Figure 4
Figure 5
Font Card Slot

Section 2
Astrojet II High-Speed In-Line Inkjet Printer Getting Acquainted
6
Printhead Carriage
This carriage, at the center of the machine, contains the five inkjet cartridges used in printing the
addresses. How these cartridges are installed and replaced will be explained later.
You can move the carriage side to side and up and down to position the address properly on the
media.
NOTE: This carriage can be raised to check for jams, and if required, for cleaning.
Media Sensor
This media sensor senses the position of the media and must be kept clean.
Operator Display Screen and Menu
When you first turn on the Astrojet II, you see the STANDBY mode screen.
MENU
Use the MENU to select or change one of the following options:
•Font/Print Quality
•Barcode
•Print Speed
•Left Margin
•Direction of print
•Purge
•Counters
•Address Recovery
Figure 6

Section 2
Astrojet II High-Speed In-Line Inkjet Printer Getting Acquainted
7
NOTES:

Section 3
Astrojet II High-Speed In-Line Inkjet Printer Installation and Setup
8
Section 3 - Installation and Setup
Before using the Astrojet II for the first time, the following procedures must be performed:
•Choosing a location for the Astrojet II
•Installing the inkjet cartridges
•Plugging in the Astrojet II
•Setting up the Astrojet II
•Setting up the transport
•Adjusting for media thickness
•Positioning the address (on the media)
Choosing a Location
•Place the Astrojet II on a table or other suitably stable and level surface within cable's
length of your computer.
•Use a grounded electrical outlet. DO NOT use an adapter plug!
•Avoid using outlets that are controlled by wall switches.
•Avoid using an outlet that shares the same circuit as large electrical machines or
appliances.
•Protect the Astrojet II from excessive heat, dust, and moisture - avoid placing it in direct
sunlight.

Section 3
Astrojet II High-Speed In-Line Inkjet Printer Installation and Setup
9
Installing the Inkjet Cartridges
The five replaceable (and interchangeable) inkjet cartridges the Astrojet II uses for printing are
installed as follows:
•Remove a print cartridge from its packaging taking care not to touch the copper
contacts, the metal plate, or the gold printhead.
•The cartridges are held in place by vertical brackets mounted on the inkjet carriage.
•With the cartridge's 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.
•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.
Figure 7
Repeat this procedure for each of the remaining 4 cartridges.
Plugging in the Astrojet II
Make sure that the main power switch of the Astrojet II is in the OFF position.
1. Connect one end of the power cord to the back of the Astrojet II in the corresponding
receptacle.
2. Plug the other end into a 120 VAC, 60Hz grounded outlet.
CAUTION: DO NOT use an adapter plug!

Section 3
Astrojet II High-Speed In-Line Inkjet Printer Installation and Setup
10
Setting up the Astrojet II
Connecting the Printer
In order for your computer and the Astrojet II to work together, you need to connect them with a
parallel cable. The cable is connected between the parallel port on the computer and the printer.

Section 3
Astrojet II High-Speed In-Line Inkjet Printer Installation and Setup
11
NOTES:

Section 4
Astrojet II High-Speed In-Line Inkjet Printer Operating the Astrojet II
12
Section 4 - Operating the Astrojet II
Because the Astrojet II is controlled by the computer to which it is connected, its operation is virtually
automatic. Once the computer and its software have been properly setup and the Astrojet II has been
supplied with media and ink cartridges, the Astrojet II is ready to operate. The computer, in turn,
sends the appropriate address information to the Astrojet II. The Astrojet II then prints these
addresses on the media.
This section, which explains how the Astrojet II is used on a regular basis, is divided into four main
categories:
•Starting Up
These are the daily start-up steps you perform each time you turn the machine on.
•Preparing a Job
How to get the Astrojet II ready for a particular addressing run.
•Running a Job
How to start a particular addressing run and keep it going.
•Printing Tips
We have supplied some hints and suggestions that will help you use the Astrojet II most
efficiently.
Starting Up
Each time you turn on the Astrojet II or after it has been idle for several hours, the following step
needs to be performed:
Running a Test Envelope
Use the TEST button to print a test pattern. Use this option to check that the address position is
correct. If you push the TEST button, only one piece will be run. Check the print quality. If the quality
is poor, purge the heads as described in section 2.
NOTE: For best results run test pattern and purge in Executive Plus Quality Mode.
Preparing a Job
When printing addresses the Astrojet II is very flexible. It allows any necessary settings to be made
from the MENU. A description of these settings and adjustments follows.
NOTE: The Astrojet II must be off-line for settings to be changed.
Clearing the Counter
To reset the piece counter to 0 at the beginning of a new job, proceed as follows:
•Press the reset button on the control panel. It will clear the counter and buffer memory.

Section 4
Astrojet II High-Speed In-Line Inkjet Printer Operating the Astrojet II
13
Print Quality/Font
To select print quality, proceed as follows:
There are three print qualities available:
•Executive Plus Quality This setting provides the darkest print quality (600 x 300
DPI) and the slowest speed.
•Letter Quality This setting provides medium print quality
(300 x 300 DPI) and speed.
•Draft Quality This setting is the lightest print quality
(150 x 150 DPI) of the three and the highest speed.
Setting Print Quality
1. Turn printer off-line.
2. Use the PREVIOUS or NEXT button to bring PRINT QUALITY to the top line.
3. Press the SELECT button, the asterisk will disappear.
4. Use the PREVIOUS or NEXT button to scroll to the desired quality.
5. Press the SELECT button to lock in the selection, the asterisk will reappear.
6. Press the NEXT button until the PRINT SPEED is in the top line.
7. Press the SELECT button and the asterisk will disappear.
8. Use the NEXT button to scroll to the desired speed. (EPQ=12 IPS, LQ=25 IPS, DQ=50 IPS).
9. Press the SELECT button to lock in the selection, the asterisk will reappear.
Installing a Font Card
To use external fonts proceed as follows.
•Turn Astrojet II power off.
•Insert font card in its socket.
•Turn the Astrojet II power on.
Bar Code
Use this option to tell the Astrojet II where to print the U.S. Postal Service POSTNET bar code.
1. Turn printer off-line.
2. Use the PREVIOUS or NEXT button to bring BAR CODE to the top line.
3. Press the SELECT button, the asterisk will disappear.
4. Use the PREVIOUS or NEXT button to select the desired barcode position.
5. Press the SELECT button to lock in the selection, the asterisk will reappear.
To set the direction of print, proceed as follows.
1. Turn printer off-line.
2. Use the PREVIOUS or NEXT button to bring DIRECTION to the top line.
3. Press the SELECT button, the asterisk will disappear.
4. Use the PREVIOUS or NEXT button to select the desired direction.
5. Press the SELECT button to lock in the selection, the asterisk will reappear.

Section 4
Astrojet II High-Speed In-Line Inkjet Printer Operating the Astrojet II
14
NOTE: When printing in reverse the Astrojet II right justifies and requires all addresses to
have lines of equal length. The easiest way to do that is to place a non-printing
character in a fixed position on one line in each address label. A good choice is
ASCII character #0142 (Ä).
Purging the Print Cartridges
To purge the printer, proceed as follows:
1. Turn printer off-line.
2. Use the PREVIOUS or NEXT button to bring PURGE to the top line.
3. Press the SELECT button, wait for the printhead to lower, feed media under the
printhead.
NOTE: Purge in Executive Plus Quality mode for best results.
Address Recovery
To direct the printer to go back and reprint a certain number of addresses (up to 8) which might have
been lost due to a jam, proceed as follows:
1. Turn printer off-line.
2. Use the PREVIOUS or NEXT button to bring ADDRESS RECOVERY to the top line.
3. Press the SELECT button, the asterisk will disappear.
4. Use the PREVIOUS or NEXT button to the desired address.
5. Press the SELECT button to print the addresses.
Vertically Positioning the Address
To ensure that the address prints at the proper vertical position, reposition the inkjet carriage as
follows:
1. Loosen the black thumbscrew so the carriage can slide forward and backward.
2. Move the carriage to the desired address location. Use the TEST button to verify the
correct location.
3. Lock the carriage in place by tightening the thumbscrew.
NOTE: Make sure that the tracking wheels rest on belts, not between.
Horizontally Positioning the Address
To ensure that the address prints at the proper horizontal position, proceed as follows:
1. Turn printer off-line.
2. Use the PREVIOUS or NEXT button to bring LEFT MARGIN to the top line.
3. Press the SELECT button, the asterisk will disappear.
4. Use the PREVIOUS or NEXT button to set the margin to the desired location.
5. Press the SELECT button to lock in the selection, the asterisk will reappear.

Section 4
Astrojet II High-Speed In-Line Inkjet Printer Operating the Astrojet II
15
Running a Job
Adjusting the Transport Table
1. Align side guides and belts with the media as it is being fed out of the feeder.
2. The belts are adjusted by sliding the belt guides from underneath the Astrojet II while the
belts are turning.
3. Adjust the speed of the feeder so that there is at least 9" gap between the leading edges
of addresses. Longer addresses may require a larger gap.
Figure 8
4. Make sure that the ON-LINE indicator key is lit, indicating that the Astrojet II is on-line.
At this point, start sending addresses from the computer.
NOTE: Do not press the reset button while the Astrojet II is receiving data from the
computer. The Astrojet II may hang up and the data in the buffer will be lost.

Section 4
Astrojet II High-Speed In-Line Inkjet Printer Operating the Astrojet II
16
Monitoring the Job
The Astrojet II may be taken off-line by pressing the ON-LINE key without affecting the addressing
job. Up to 3 addresses may be printed before unit goes off-line. The media will resume printing at
exactly the same point when the Astrojet II is put back on-line.
IF A JAM OCCURS, DO NOT TURN OFF YOUR UNIT! Remove jam as described in Section 5.
Printing Tips
Tips on Types of Media
The Astrojet II 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 print quality and ink drying
time. It is best to test each new type of media to be run to determine performance levels.
NOTE: Since coated and plastic types of “paper” do not easily absorb ink, smearing may
occur. On the other hand, paper that is too porous may get “fuzzy,” as opposed to
crisp printouts. Another cause of “fuzzy” printouts is excessive buildup of dust within
the machine, or the printhead is too far away from the media.
Be aware, that when printing in the Executive Plus mode, drying time for the ink is
longer than in the other modes. Also, when humidity is high, drying time is
increased.
Tips on Media Thickness
The Astrojet II will handle pieces up to 3/8" thick (0.375"). However, they must be flexible enough to
pass through the rollers. All folds must be crisp and even. Also, the thicker the media, the less that
may be loaded into the hopper at a single time.
Although the minimum allowable thickness is 0.008", we recommend that you carefully fan these
pieces before loading to avoid double feeding.
Tips about Bound Pieces
DO NOT use stapled pieces in the Astrojet II.
DO NOT use paper-clipped pieces in the Astrojet II.
CAUTION: 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 use of these methods. Also, the
USPS does not accept this type of mail for its automated equipment.

Section 4
Astrojet II High-Speed In-Line Inkjet Printer Operating the Astrojet II
17
NOTES:

Section 5
Astrojet II High-Speed In-Line Inkjet Printer Operator Maintenance
18
Section 5 - Operator Maintenance
This section shows how to replace inkjet cartridges and clear paper jams quickly and safely. Other
problems such as no printing, poor print quality, etc., are also covered. Special tips and suggestions
to help you increase efficiency and avoid problems are also included.
Replacing the Inkjet Cartridges
The Astrojet II inkjet cartridges must be replaced when out of ink, when print quality is poor, or when
purging and cleaning have not helped.
The approximate life of inkjet cartridges based on 20 characters per address line is:
Executive Plus Quality 50,000 addresses
Letter Quality 100,000 addresses
Draft Quality 200,000 addresses
Figure 9
To replace an inkjet cartridge:
•To remove the cartridge, pull the top toward you until the cartridge is free of the retaining
clip (see above). Lift the cartridge up and out of holder.
•Remove a new print cartridge from its packaging, taking care not to touch the copper
contacts, the metal plate, or the gold printhead.
•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.
•Now, press the upper part of the cartridge toward the bracket until it clicks into place
under the retaining clip of the bracket.