AstroJet M1DX Manual

AstroJetTM M1DX
COLOR DUPLEX
PRINTER
OPERATOR GUIDE
ASTRO MACHINE CORP.
630 Lively Blvd.
Elk Grove Village, IL 60007
Phone: [phone]
Fax: [phone]
www.astromachine.com

SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
OBSERVE SAFETY RULES WHEN OPERATING M1DX PRINTER.
BEFORE USING PRINTER, READ THIS MANUAL CAREFULLY AND FOLLOW
RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS:
Keep hands, hair, and clothing clear of rollers and other moving parts.
Avoid touching moving parts or materials while machine is in use. Before clearing a jam, be sure
machine mechanisms come to a stop.
Always turn machine off before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
Power cord and power supply supplied with machine. Plug it into a properly grounded,
easily accessible wall outlet near machine. Failure to properly ground machine can result in severe
personal injury and/or fire.
Power cord and wall plug are primary means of disconnecting machine from power supply.
DO NOT use an adapter plug on line cord or wall outlet.
DO NOT remove ground pin from line cord.
DO NOT route power cord over sharp edges or trap it between furniture.
Avoid using wall outlets that are controlled by wall switches or shared with other equipment.
Make sure there is no strain on power cord caused by jamming it between equipment,
walls or furniture.
DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified
service representative. Report any cover damage to your service representative.
This machine requires periodic maintenance. Contact your authorized service representative for required
service schedules.
To prevent overheating, do not cover vent openings.
Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Astro Machine Corp., 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 Corp. nor any of its agents or employees shall
be responsible for any inaccuracies contained herein.
AstroJetTM is a registered trademark of Astro Machine Corp.
Memjet®is a registered trademark.
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
i
Table of Contents
SECTION 1 –Getting Acquainted 1
Front View 1
Rear View 2
Print Engine View 3
Ink Tank Dock View 4
Top Printer Control Panel Button/LED Indicators 5
Duplex Printer Control Panel Button/LED Indicators 6
SECTION 2 –Assemble and Install Printer 7
Contents of Packaging 7
Choose a Location 7
Unpacking and Set-up 7
Remove Transport Locks 8
Remove Service Station Transport Tab and Shipping Tape 9
Install Adapter Feet on Top Printer 10
Install Top Printer on Duplex (Bottom) Printer 11
Connecting Printers 12
Overview: Install Firmware and Printer Driver on Top Printer 13
Printer Driver (Top Printer) 14
Uninstall Existing Printer Driver 14
Install Printer Driver 16
Install Over USB Connection 16
Install Over Network Connection, Version A 18
Install Over Network Connection, Version B 21
Install Firmware on Top Printer 23
Set Up Top and Bottom Printer Communication 25
Install Ink Tanks 26
Install Printhead Cartridge 28
Removing Head Media Guide 31
Install/Remove Envelope Attachment Spacers 32
Install Drop Tray or Optional Conveyor 33
Setting up Feed 35
Adjust Printer Alignment 36
SECTION 3 –Operating Printer 38
Duplex Printer Driver Properties 38
General Tab 38
Layout Tab 40
Color Tab 42
Import/Export Tab 42
Services Tab 43
Using Duplex Printer Toolbox 44
Drop-Down Menu Options 44
Maintenance Drop-Down 51
Service Drop-Down 51
Print Drop-Down 52
Updating Firmware using “.bin” Files 53

TABLE OF CONTENTS
ii
SECTION 4 –Maintenance 54
Replacing Ink Tanks 54
Cleaning Ink Tank Contacts 56
Cleaning/Replacing Printhead Cartridge 58
Replacing Service Station 64
Replacing Ink Waste Tray 68
Jams in Printer 69
Cleaning 70
Shipping or Transporting Printer 72
SECTION 5 –Troubleshooting Guide 76
Memjet®Printhead 76
Printer 77
Errors and Warnings 78
Appendices 84
Appendix A –Duplex Printer Specifications 84
Appendix B –Supplies and Optional Hardware 85
Index 86
Printer Maintenance Schedule 92

TABLE OF CONTENTS
iii
NOTES
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SECTION 1
GETTING ACQUAINTED
1
SECTION 1 –Getting Acquainted
Front View
1.
Power (ON/OFF) Switch –Use to turn power ON or OFF during idle time
and maintenance.
2.
LED Status Indicators –Sensors show status of Printer, Feeder and Duplex
Printer. White = Standby. Green = Ready. Red = Not Ready or Stopped.
3.
Duplex Feeder –Feeds media from the top printer to the Duplex Printer.
4.
Print Engine Access –Open door to access the Print Engine for cleaning,
maintenance and service.
5.
Storage Compartment –Store extra media and/or supplies.
6.
Ethernet Ports –Used to connect to Top Printer and to connect to Network
(if necessary). Ports are interchangeable.
7.
Main Power Switch, Receptacle and Fuse –Plug in power cord here. Switch
turns main power ON/OFF. (Use Control Panel LED Power switch to turn off
machine for cleaning and maintenance). Fuse protects Printer’s electronic circuits.
8.
Drop Tray –Removable tray catches printed media in both double-sided and
single-sided modes.

SECTION 1
GETTING ACQUAINTED
2
Rear View
1.
Duplex Feeder –Feeds media from the Top Printer into the Duplex Printer.
Feeder folds down to use Top Printer as a single-sided Printer.
2.
Duplex Feeder Cover Latch –Opens cover to clear media jams.
3.
Power Button –Turns power to the Duplex Printer ON/OFF.
4.
Printer Status Indicators –White, Green and Red LEDs show Printer status at a
glance. White is ready or waiting. Green is OK to print. Red indicates a problem.
5.
Print Engine Access Door –Access the Print Engine for maintenance, cleaning
and service. Once unlatched, Print Engine slides out on drawer-type tracks.
6.
Storage Compartment –Store extra ink, printheads and media.
7.
Print Engine Latch –Unlock to slide Print Engine out of Cabinet for cleaning,
maintenance or service.
8.
Print Engine Handle –Use to slide Print Engine in and out of Cabinet.

SECTION 1
GETTING ACQUAINTED
3
Print Engine View
1.
Printhead Latch –When closed, connects Ink Revolver Couplings with Printhead
Cartridge. When opened, retracts Ink Couplings from Printhead Cartridge and
provides access to Printhead Cartridge for cleaning and replacement.
WARNING! Never attempt to open Printhead Latch manually, severe damage will
result. Use Printhead Release button function in Toolbox on your PC or press
Printhead Latch Release Button (See #4 below).
2.
Ink Revolver Couplings –Connect ink hoses to Printhead Cartridge.
Printhead Latch extends and retracts couplings from Printhead.
3.
Printhead Cartridge –Memjet®Printhead produces an 8.5" wide full color print area.
4.
Printhead Latch Release Button* –Button inside opening will initiate a Printhead
Latch release cycle. If system is primed, runs a full system deprime cycle before
Latch is released. Lightly press button with a non-conductive tool.
*Same function can be accessed through Printer Toolbox User Interface screen on your computer.
5.
Print Ink Channels Button* –Prints 5 bars (1 bar from each ink tank) to indicate
how well Printhead Nozzles are working. Press button with a non-conductive tool.
*Same function can be accessed through Printer Toolbox Diagnostics screen on your computer.
6.
Clamshell Latches –Lift both latches at same time to open top half of Print Engine.
DO NOT open while Printer is operating. DO NOT open Clamshell more than
60 degrees. DO NOT let Clamshell drop, close it gently.
7.
Bubble Level –Used to ensure Printer is level and ready to print.

SECTION 1
GETTING ACQUAINTED
4
Ink Tank Dock View
1.
Ink Tank Securing Latches –Used to hold Ink Tanks in slots.
NOTE: Make sure both sides at bottom part of latch are engaged.
2.
Ink Tanks –Printer has 5 Ink Tanks: Cyan, Yellow, Magenta, Black, Black
3.
Ink Waste Tray –Catches any waste ink produced by system. Tray is filled with
absorbent material. Tabs located at left and right sides of tray secure tray to print
engine frame. Please be sure tabs click in to secure tray.
4.
Service Station –Cleans Printhead Cartridge of excess ink and debris, keeps
Printhead hydrated and protected when not in use, captures ink used to keep
nozzles clear, and acts as a base to support media during printing.

SECTION 1
GETTING ACQUAINTED
5
Top Printer Control Panel Button/LED Indicators
Control Panel has three buttons with LED indicators.
POWER (ON/OFF) –Turns Printer power ON and OFF.
Turns off power for cleaning and maintenance
PAPER (STOP JOB/RESUME) –Stops Paper Feed or
Resumes Printing.
Press to Stop Paper Feed Immediately.
Printer will clear media in Printer and stop.
Press to Resume Printing. Restart printing after a paper feed error
(such as a paper jam or running out of paper).
CANCEL (CANCEL JOB) –Cancels a Job.
Press to Cancel a Job. Once Printer has stopped, pressing this button clears job from Printer and Print
Queue in Driver. NOTE: Cancelled Jobs must be reloaded before printing can resume.
MORE TROUBLESHOOTING GUIDES on page 76.

SECTION 1
GETTING ACQUAINTED
6
Duplex Printer Control Panel Button/LED Indicators
Control Panel has one power button and a diagram with three
LED indicators.
POWER (ON/OFF): Turns Duplex Printer power ON and OFF.
Turns off power for cleaning and maintenance.
Indicator LEDs: Show readiness status in Printer, Duplex Feeder
and Duplex Printer.
White: Ready –No Job loaded
Green: Ready –Job loaded
Red: Not Ready –Action Required in area(s) showing
red. (Clear media jams, Duplex Feeder not set correctly
for type of job sent, out of paper, out of ink, etc.)

SECTION 2
ASSEMBLE/INSTALL PRINTER
7
SECTION 2 –Assemble and Install Printer
Contents of Packaging
1.
Duplex Printer
2.
Ink Tanks –Cyan, Magenta, Yellow, Black, Black
3.
Printhead Cartridge
4.
Envelope Attachment Spacers (pkg. of 2)
5.
AC Power Cord
6.
Ethernet Cable (to connect Top Printer and Duplex Printer)
7.
Adapter Feet for Top Printer (pkg. of 2)
8.
Operator Manual
9.
Driver/Firmware Software CD
Before using Printer:
Choose a location for Duplex Printer
Unpack and assemble Duplex Printer
Remove Print Engine Transport Locks
Remove Service Station Transport Tab and Shipping Tape
Install Adapter Feet on Top Printer
Install Top Printer on Bottom (Duplex) Printer
Plug in Printer and connect it to computer or network
Update/Install Firmware and Printer Driver on Top Printer
Set up Top and Duplex Printer communication
Install Ink Tanks
Install Printhead
Set up feed on Printer
Choose a Location
Position Duplex Printer at least 9" from any walls. Use Bubble Gauge mounted on Print Engine
(or a small level) to make sure Duplex Printer is level. Protect Printer from excessive heat, dust, and moisture.
Avoid placing it in direct sunlight.
Unpacking and Set-up
Remove Duplex Printer from carton. Remove all packing tape.

SECTION 2
ASSEMBLE/INSTALL PRINTER
8
Remove Transport Locks
1. Remove the Non-operator Side Cover.
(6 screws.)
2. Remove 2 screws from Print Engine Support
Bracket [A].
3. Open Print Engine Access Door.
Remove 4 screws securing Transport Locking Bracket
[B] to Frame (Under Handle). Remove Bracket and
save for future use.
4. Remove two Duplex Feeder Transport Brackets.
Remove screws [C] securing the two Brackets to the
Duplex Feeder and Duplex Cabinet. (3 screws per
side). NOTE: Save all Transport Brackets and screws
for later use.
5. Reinstall Non-operator Side Cover.

SECTION 2
ASSEMBLE/INSTALL PRINTER
9
Remove Service Station Transport Tab and Shipping Tape
1. Open Print Engine Access Door. Unlatch and pull out
Print Engine.
2. Release two latches [A] (one on either side of Print
Engine). Open top half of Clamshell by lifting both levers
at same time.
CAUTION
HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING PRINT
ENGINE CLAMSHELL TO PREVENT DAMAGE.
DO NOT ALLOW CLAMSHELL TO DROP OR SLAM CLOSED.
TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING
CLAMSHELL MORE THAN 60°.
3. Remove cardboard Transport Tab [A] from
Service Station.
4. Remove tape [B] securing Head Media Guide.
(If necessary, wipe tape residue off Head Media
Guide surface [C].)
5. Carefully close and latch Upper Clamshell. Slide
and latch Print Engine into cabinet. Close Side
Door. Return Duplex Feeder to double-sided
printing position.

SECTION 2
ASSEMBLE/INSTALL PRINTER
10
Install Adapter Feet on Top Printer
Install two Adapter Feet on the operator side of the
Printer. These will help guide and stabilize the Top
Printer onto the Bottom Printer.
1. Remove the two Rubber Feet from the operator
side (Control Panel side) of the Top Printer.
2. Install two Adapter Feet (included with Duplex
Printer) on the operator side of the Top Printer.

SECTION 2
ASSEMBLE/INSTALL PRINTER
11
Install Top Printer on Duplex (Bottom) Printer
CAUTION Two people should lift and position the Top Printer onto the Duplex (Bottom) Printer.
1. [A] Lower the Duplex Feeder on the
Duplex Printer.
[B] Carefully place feet on the exit end of
the Top Printer into the two holes located
in front of the Duplex Feeder on the
Duplex (Bottom) Printer.
[C] Place the feet on the entry end of
the Top Printer into the two holes
located at the exit end of the Duplex
(Bottom) Printer.
NOTE: Make sure the Top Printer sits flat on the Duplex (Bottom) Printer. Do not connect the
Top Printer to the Duplex Printer with the short network cable at this time.
2. Double-Sided Printing: Raise the Duplex Feeder [D] until it
attaches magnetically to the exit end of the Top Printer.
Single-Sided Printing: Lower the Duplex Feeder Assembly.
3. Position the Drop Tray or
Conveyor for single or double-
sided printing as shown.

SECTION 2
ASSEMBLE/INSTALL PRINTER
12
Connecting Printers
Plugging in Printer
Plug power cord (included with Duplex Printer) into receptacle [1] at rear of
Duplex Printer. Plug other end into an appropriate wall receptacle. Internal
power supplies in Top Printer and Duplex Printer are rated 115 to 240VAC,
50/60 Hz.
CAUTION
DO NOT USE ADAPTER PLUGS OR EXTENSION CORDS TO
CONNECT PRINTER TO WALL OUTLET.
DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES.
DO NOT USE OUTLETS SHARING SAME CIRCUIT WITH
LARGE ELECTRICAL MACHINES OR APPLIANCES.
CHECK POWER CORD! USE 115V POWER CORD ONLY
WITH 115 VAC OUTLETS. USE 220V POWER CORD ONLY
WITH 220 VAC OUTLETS.
Connecting to Computer or Network
IMPORTANT
For the initial (first time) installation, DO NOT connect the Top
Printer to the Duplex Printer (via Ethernet cable) until after the Top
Printer's firmware and Printer Driver have been updated/installed.
If Top Printer is connected to a computer via USB port [2]:
Plug Ethernet Cord (included with Duplex Printer) into Ethernet Port on Top Printer [3] and either
Ethernet Port on Duplex (Bottom) Printer [3A].
If Top Printer is connected to a network via Ethernet port:
[A] Plug Ethernet Cord (included with Duplex Printer) into Ethernet Port on Top Printer [3] and either
Ethernet Port on Duplex (Bottom) Printer [3A].
[B] Move the network Ethernet cable from the Top Printer to the second Ethernet port on the Duplex
(Bottom) Printer. (This connects both Printers to the network.)
See “Network Connection Setup” in “Using Duplex Printer Toolbox” section.

SECTION 2
ASSEMBLE/INSTALL PRINTER
13
Turning Power ON and OFF
Powering Up Printer:
1. Press Main Power Switch on Rear Panel.
2. Press Power Button on Control Panel.
Powering Down Printer:
CAUTION
WHENEVER POWERING DOWN UNIT, ALWAYS:
1. PRESS POWER BUTTON ON CONTROL PANEL.
2. WAIT FOR PRINTER TO STOP PROCESSING.
3. THEN PRESS MAIN POWER SWITCH ON REAR PANEL.
Overview: Install Firmware and Printer Driver on Top Printer
BEFORE YOU BEGIN:
The firmware and Printer Driver on the Top Printer have to be updated and/or installed. If you are using your
existing Printer as the Top Printer follow the procedure below to update the firmware and install a new Printer
Driver. If the Top Printer is new (never before installed), you can skip Step 1.
1. If using an existing (previously installed) Top Printer: Uninstall the current Printer Driver.
See “Uninstall Existing Printer Driver.”
If the Top Printer is new (never before installed): Skip to Step 2.
2. Install Printer Driver on Top Printer. See “Install Printer Driver (Top Printer)”.
3. Update the firmware on the Top Printer. See “Update Firmware on Top Printer”.
4. See “Set Up Top and Bottom Printer
Communication”
Open the Printer Toolbox.
Open Service Menus using the password.
Open Printer Control Configuration
Check boxes for both “Enable Duplex” and
“Duplex Master” options. Click “Submit”.
5. Use the short network cable (included) to connect
the Top and Duplex Printers.

SECTION 2
ASSEMBLE/INSTALL PRINTER
14
Printer Driver (Top Printer)
Before installing the Printer Driver on the Top Printer: If the Top Printer already has a Printer Driver installed,
you will have to uninstall the existing Printer Driver from the Top Printer. If the Top Printer is new or has never
been installed you can proceed to “Install Printer Driver”. NOTE: The Duplex Printer's software is preinstalled.
The Duplex Printer should not be connected to the Top Printer for this step.
Uninstall Existing Printer Driver
NOTE: If installing a new Top Printer (never installed), you can skip this step and
proceed to “Install Printer Driver”.
1. Make sure Top Printer is plugged in and turned ON,
USB is disconnected and that no jobs are pending.
The Duplex Printer should not be connected to the
Top Printer for this step.
2. Open “All Programs”, then find and select the
Memjet Folder.
3. Open the “M Series Driver” folder and click on “Uninstall”.
4. Select (highlight) the desired Printer and click
“Remove One”.
NOTE: Clicking “Remove All”without
selecting a Printer will remove all listed
Printers and associated Drivers.
5. The next window asks if you want to
continue. Click “Yes”.
6. The Printer Driver will be uninstalled.