Rena AS-150 User manual

AS-150 PRINTER
SERVICE MANUAL
Rev 10-14-15

SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
OBSERVE SAFETY RULES WHEN OPERATING THE AS-150 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 machine, or performing any
maintenance covered in this manual.
Use power cord supplied with machine. Plug it into a properly grounded, easily accessible wall
outlet located 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 Neopost USA, its designated agents, 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 Neopost USA nor any of its agents or employees shall be responsible for any inaccuracies
contained herein.
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 –Installation 2
Contents of Packaging 2
Assembling Printer 2
Install Rear Media Support 3
Install Rear Media Guide 3
Connecting Printer 4
Install Inkjet Cartridges 5
Set up Feed 6
Install Printer Driver 7
BIOS Manager 8
SECTION 2 –Troubleshooting 9
Service Diagnostic Tests 16
Sensor Test 16
SECTION 3 –Functional Operation 17
Sequence of Operation 17
Printer Control Panel 18
Printer Control Panel 19
Purge While Printing 21
Printer Driver Properties 22
PC Board and Electrical Component Location 25
SECTION 4 –Adjustments 26
Drive Belt Tension Adjustment 26
Encoder Belt Tension Adjustment 27
Output Voltage Adjustment 28
Media Sensor Adjustment 29
LCD Display Adjustment 30
Brake Adjustment 31
SECTION 5 –Disassembly/Assembly Procedures 32
Tools Required 32
Basic Disassembly 32
Replacing Separator Tips 34
Service Disassembly Procedures 35
SECTION 6 –Maintenance 47
Inkjet Cartridge 47
Jams in Printer 49
Replacing Sheet Separators 49
Cleaning 50
APPENDIX A –Printer Specifications 51
APPENDIX B –Supplies 52
INDEX 53

SECTION 2
INSTALLING PRINTER
2
SECTION 1 –Installation
Contents of Packaging
1.
AS-150 Printer
2.
Power Cord
3.
Software
4.
Side Guides
5.
Rear Media Support & Guide
6.
Operator Manual
Assembling Printer
Tools required: Standard #2 Phillips head screwdriver.
Install Side Guides
1. Remove two screws from Side Guide Blocks.
2. Position Side Guide screw holes so they
align with holes in Side Guide Blocks.
3. Insert screws removed in Step 1 and
tighten so Guides are firmly attached to
Side Guide Blocks.

SECTION 2
INSTALLING PRINTER
3
Install Rear Media Support
1. Install Rear Media Support using two
screws [A] (included) onto Rear Center
Plate (as shown).
Install Rear Media Guide
1. Insert Adjusting Knob [A] through Rear
Media Guide and Rear Media Support.
Screw into rectangular washer [B].

SECTION 2
INSTALLING PRINTER
4
Connecting Printer
Plugging in Printer
Make sure Printer’s Main Power Switch is turned OFF.
1. Connect one end of power cord to rear
receptacle on Printer.
2. Plug other end into a 115-220 Volt AC,
50/60 Hz. grounded outlet.
CAUTION
DO NOT USE ADAPTER PLUGS OR
EXTENSION CORDS TO CONNECT
PRINTER TO WALL OUTLET.
DO NOT USE WITH OUTLETS
CONTROLLED BY WALL SWITCHES.
DO NOT USE WITH OUTLETS THAT
SHARE SAME CIRCUIT WITH LARGE
ELECTRICAL MACHINES
OR APPLIANCES.
Connecting to Computer
USB Port: Plug USB cable into USB connector.
Cable used to connect Printer to computer must
not exceed 6 feet long.

SECTION 2
INSTALLING PRINTER
5
Install Inkjet Cartridges
Printer has 3 Inkjet Cartridges. To install Cartridges:
1. Remove Inkjet Cartridge from packaging.
Take care not to touch copper contacts,
metal plate, or gold printhead. Remove
protective tape from Printhead.
2. Open Latch Lever mounted on Inkjet
Cartridge Holder.
3. With Cartridge’s Printhead pointing
down, slide Cartridge into Holder. Push
down and toward contacts in Holder.
4. Make sure Cartridge is seated in Holder.
Close Latch Lever to secure Cartridge.
DO NOT force Latch Lever into place.
5. Repeat Steps 1-4 for remaining
Inkjet Cartridges.
Ink in Cartridge may be
harmful if swallowed.
Keep new and used
Cartridges out of reach of
children. Discard empty
Cartridges immediately.

SECTION 2
INSTALLING PRINTER
6
Set up Feed
Printer has two Sheet Separators, two Side Guides, and a Rear Media Support and Guide.
Adjust Sheet Separators individually as follows:
1. Move Side Guides to access locking screws.
2. Loosen locking screw(s) [A] (as shown) and
raise Separator.
Tighten locking screw to hold Separator in
raised position.
3. Place media under Separators. It is best to
place media in center position on Table.
4. Loosen Separator locking screw.
Place Separator on media and tighten
locking screw.
Repeat for remaining Separator.
5. Adjust Side Guides so they are about 1/32"
from sides of media. Tighten locking screws on
Side Guides.
Set Side Guides to direct media so Printheads
print on desired print area of media (top edge,
middle, bottom edge).
6. Adjust Rear Guide by loosening locking screw
[B]. Slide Guide so media is raised
approximately 1/2" above Rear Media
Support. Tighten locking screw.
7. Test feed media by pressing ON LINE key,
then ENTER key. Press ENTER to stop
feeding, then press ON LINE to stop Printer.

SECTION 2
INSTALLING PRINTER
7
Install Printer Driver
Install Printer Driver (CD included) on your computer.
NOTE: Driver for Printer should start when installed. If it does not, use steps below.
1. Close any applications running on your computer.
Restart computer before installing Driver.
2. Install CD in CD drive: Click “Open folder to view
files”. Then select and double-click “Setup.exe”.
3. “Add, Update or Delete Printer”window opens.
Click “Add New Printer”.Click Next>.
4. “Install Printer Driver”
window opens. Select
manufacturer and model of
your printer. Click Next>.
5. Select USB Printer Port.
Click Next>.
6. Next screen allows you to
“Name Your Printer”.
Unless another printer has the
same name on your system or
network, ignore this step and
click Next>.
7. Click Finish to complete
the installation.
8. Check in “Devices and
Printers”that Printer is
available and active.

SECTION 2
INSTALLING PRINTER
8
BIOS Manager
BIOS Manager is used to upgrade the BIOS in the Printer. Occasionally you may receive a new BIOS for
the Printer. It must be loaded in the Printer's flash ROM. This is where the BIOS Manager comes in. After
receiving new BIOS either via e-mail or on a disk, it has to be loaded into the BIOS Manager software.
1. Make sure that the Printer is connected to the computer via USB cable and turned ON.
2. Open the Printer CD. Find and
click “FirmwareMgr.exe” to start
the program.
3. BIOS Manager window opens.
Click “Browse” to find the new
firmware. Select the new BIOS file
from the list of BIOS.
Click on the selection.
4. BIOS Manager window opens
again. Click “Download”.
5. This returns you to the BIOS
Manager window. Check that the
“Flashing:”line is turning green
Program installs new the BIOS
firmware on the Printer. Check that
the Printer Display shows:
“A firmware update is in
progress…”
6. Download is complete when the Printer restarts itself or when you see that the “Download”button is
active again. Click “Close”.
WARNING!
DO NOT TURN OFF OR DISCONNECT PRINTER DURING DOWNLOAD
PROCESS. DOING SO WILL DAMAGE MAIN PROCESSOR PC BOARD.

SECTION 2
TROUBLESHOOTING
9
SECTION 2 –Troubleshooting
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 power cord is plugged in.
Check that power outlet is live.
Check fuse in Main Power Switch.
Replace with fuse of same rating.
Bad Controller PC Board. Replace.
Bad Power Supply. Replace.
Interface Communication Problems
CONDITION
PROBLEM
SOLUTION
Printer does not respond
to software
Connection problems
Check that port is communicating
with Printer via USB cable. If not,
replace cable.
If port cannot communicate using
another USB cable, check Printer.
If port cannot communicate using
USB cable and Printer is OK, check
USB port.
Check USB cable for breaks/damage.
If so, replace cable.
Poor connection between
Printer and computer
Turn Printer OFF and ON again.
Check connections.

SECTION 2
TROUBLESHOOTING
10
LCD Display Problems
CONDITION
PROBLEM
SOLUTION
No LCD display
Power not ON
Contrast Pot broken or maladjusted
Broken solder joint on Contrast Pot
Turn power switch ON. If still no
display, see Power Problems.
Adjust Pot or replace Display
PC Board.
(see Section 4-Adjustments)
Repair or replace Display
PC Board.
LCD shows solid line or
garbled characters
Power Supply
Static electricity
Check voltages and inspect Power
Supply connections to processor
PC Board.
Turn Printer OFF, then ON.
LCD displays solid
black line or lines
Bad Power Supply
No firmware (BIOS)
Bad processor PC Board
Check all voltages.
Install firmware.
Replace processor PC Board.
Feeding Problems
CONDITION
PROBLEM
SOLUTION
Intermittent feeding
Feed Ramp not used
Side Guides set improperly
Dirty Feed Rollers
Paper stuck together
Bad or dirty Sensor
Uneven mail piece
Feed Ramp adds a slope to media
stack and helps feeding.
Loosen Side Guides slightly.
Clean Feed Roller with distilled
water and a cloth. DO NOT use any
solvents or detergents as they may
damage Feed Rollers.
Fan media before placing it
in Printer.
Clean Sensor with compressed air
or replace it.
Tap inserts to front of envelopes
and retry.
Multiple feeds
Separator gap not set properly
Sensor bad or dirty
Media stuck together
Side Guides too close to media
Brake misadjusted
Adjust Sheet Separators to
media thickness.
Clean Sensor with compressed air
or replace it.
Fan media before feeding.
Push Side Guides away from media.
Adjust Brake
(see Section 4-Adjustments)

SECTION 2
TROUBLESHOOTING
11
Feeding Problems (continued)
CONDITION
PROBLEM
SOLUTION
Failure to feed
Side Guides too close to media
ENTER key not pressed
No power to Printer
Feed gap too tight
Feed gap too loose
Material is out of specification.
Motor ON, Feed Rollers
not turning
Clutch not engaging
Motor failure
No power
Readjust Side Guides.
Instruct user on proper operation.
Check power button is ON and
power cord is plugged in.
Adjust Separator to media thickness.
Adjust Separator to media thickness.
Maximum thickness: 0.020"
Press ENTER key, check for broken
Drive Belt and replace, check for
loose set screws on Drive Pulley or
Belt Drive Roller Pulley.
Replace Clutch.
Check or replace Motor.
See Power Problems in this Section.
Jams
Paper path obstruction
Paper not loaded properly
Feed Ramp not used properly
Separators improperly adjusted
Media curled or bent
Bad or dirty Sensor
Clear jam and remove pieces
remaining under Printhead.
Instruct operator in proper loading
of media.
Set Feed Ramp.
Adjust Separators to thickness
of media.
Uncurl media.
Clean or replace Sensor.
Worn Separator Tip
Conveyor tape (Transport Belt)
under Printhead broken
Replace Separator Tip.
Replace tape (Transport Belt).

SECTION 2
TROUBLESHOOTING
12
Printing Problems
CONDITION
PROBLEM
SOLUTION
No printing: Media is blank
after going under Printheads
Sensor did not see the piece or
send signal to print to PC Board
Clogged Cartridges
Cartridge dried out
Tape on Printhead
Cartridge not properly inserted
Cartridge empty
Power Supply voltage out of spec
Printhead Holder
Clean or replace Sensor.
Clean and purge Cartridges.
Install new Cartridge.
Remove tape.
Remove and reinsert Cartridge.
Install new Ink Cartridge.
Check voltages.
Check Flex Circuit for tears.
Print slanted or skewed
Skew within specs.
Side Guides not set properly
± 2.5° from bottom edge
of material.
Readjust Side Guides.
Gray print
Ink cartridge almost dry
Replace Ink Cartridge.
Blurry print
Dirty Printheads
Paper too porous or absorbent
Printheads scratched
when cleaned
Clean Printheads.
Use other paper.
Replace Printhead.
Printing light
Printhead clogged or dirty
Resolution of output set too low
Running low on ink
Purge and clean Printheads.
Reset to a higher resolution.
Replace Cartridge.
Print streaking
Exit Roller dirty
Printhead dirty
Clean Exit Roller with water.
Clean Printhead.

SECTION 2
TROUBLESHOOTING
13
Printing Problems (continued)
CONDITION
PROBLEM
SOLUTION
Non-uniform print quality
Check voltage from power supply
Poor Printhead connections
Adjust to 14 VDC. (See “Output
Voltage Adjustment”)
Check that Flex Circuit
connections are in place.
White lines/streaks in a
line of print
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
Wiping wrong way or too hard
drove particles into Nozzles
Cartridge low on ink
Tape covering Print Nozzle or
Vent Holes
Printhead connections not set
Bad Printhead Drive Card
Clean Cartridge.
Remove and reinsert Cartridge.
Replace Cartridge.
Replace Cartridge.
Replace Cartridge.
Instruct operator in proper
cleaning method.
(See “Cleaning Printhead”)
Replace Cartridge.
Remove tape.
Check that Flex Circuit
connections are in place.
Replace Printhead Drive Card.
Smeared ink
Coated paper preventing ink
absorption
High humidity slowing
drying time
Use fast-dry ink and/or allow
more time to dry after printing.
Use fast-dry ink and/or lower
dpi resolution.

SECTION 2
TROUBLESHOOTING
14
Print Placement Problems
CONDITION
PROBLEM
SOLUTION
Print too close to leading
or trailing edge of media
Size of media not set correctly
in Layout
Bad or dirty Sensor
Feed Ramp not used properly
Check layout in Layout for
proper size.
Clean or replace Sensor.
Set Feed Ramp.
Check location and margins in
layout software. Check that piece
on layout screen looks exactly the
way you want the piece to look.
Print too high or low
on the media
Physical location of Printhead
does not match layout template
Adjust Media Guides.
Use “0” reference point in center
of scale to help you align print
on media.
Address prints upside
down on media
Layout and/or media
direction incorrect
Change direction from Normal to
Inverted or Inverted to Normal in
Driver Properties.
Address too close to center
of media
Chosen media size in layout is
too small
Physical location of Printheads
do not match layout
Feed Ramp not set properly
Set correct media width size
in Layout.
Check image on layout screen,
adjust Media Guide or media.
Adjust Feed Ramp.
Address printing partially
off media
Chosen media size in layout is
too large
Physical location of Printheads
do not match layout
Feed Ramp not set properly
Set correct size in Layout.
Check image on layout screen,
adjust Media Guide or media.
Adjust Feed Ramp.

SECTION 2
TROUBLESHOOTING
15
Print Content Incorrect
CONDITION
PROBLEM
SOLUTION
Information being printed
is wrong, incomplete,
or garbled
Poor cable connections
Interface problem
Corrupted database file
Check USB cable:
Securely fastened at both ends.
Cable length not more than 6-ft.
Printer's internal USB cable in
good condition.
Check Printer setup at computer.
Use another database file.
Barcode does not print
Wrong font selected
No zip code in database
Barcode not enabled
If using a combined field
barcode, choose USPS
barcode font.
Put zip code field in database or
use another database.
Enable barcode.
Unwanted BOLD, Italic, or
Underlined type
Turned on in layout
Open layout and change
type style.
Not all addresses in
database print
Only some addresses in database
were selected to print
Start new job and select
entire database.
Data being lost
Database problem
USB cable connection loose
Check database program.
Check/reconnect cable.
Graphics or text have a
white line through them
Graphic or text is set between
junction of two Printheads.
Move copy or adjust media.
Software Problems
Refer to the manual for the application software being used.

SECTION 2
TROUBLESHOOTING
16
Service Diagnostic Tests
TEST PRINT key
Press TEST PRINT to place Printer into Test Print mode. Press ENTER to print a test sheet.
NOTE: Remove all media from Printer before performing these tests.
To access Test Print mode, press and hold TEST PRINT until “Service Menu” is displayed on Printer
Control Panel. Use “+” or “–” keys to step through test options.
Drive Speed Test
Press ENTER to start Main Drive Motor and display Belt Speed in inches per second. Press ENTER again
to stop Main Drive Motor. If Main Drive Motor does not start, Main Drive Motor circuitry has a problem.
No reading in inches per second indicates an Encoder problem.
Motor Test
Press ENTER to start Main Drive Motor. Press ENTER again to stop Main Drive Motor. Main Drive
Motor not starting indicates a problem in Main Drive Motor circuitry.
Clutch Test 1
Press ENTER to start Main Drive Motor and turn Feed Clutch ON. Press ENTER again to turn Feed
Clutch OFF. If Clutch does not engage there is a problem with Clutch circuitry.
Clutch Test 2
This test is designed to operate Clutch in an ON and OFF mode. Selecting this test and pressing ENTER
causes Clutch to actuate and de-actuate in sequence.
Sensor Test
Press ENTER to display state of Media Sensor. “Uncovered”displays when Sensor is NOT covered.
“Covered”displays when Sensor IS covered. Use a strip of paper inserted in Sensor area to test its
function. Failure to switch between the two messages indicates a problem in Sensor circuitry.
Power Supply Test
Press ENTER to display voltage reading of Main Power Supply. Nominal reading is between 13.5 and 14.5
volts. Power Supply may need adjusting to bring value within nominal range.
Encoder Test
Press ENTER to display current Encoder Count Reading. Move Exit Roller. If number does not increase,
an Encoder failure is indicated.
Keyboard Test
Press ENTER to test function of individual keys on keyboard. When a key is pressed, display shows key
name. To exit this test, power Printer OFF.
Ink Levels
Ink Levels in each of Cartridges are displayed as a percentage in this mode. This only displays properly if
operator resets system when a new Cartridge is installed.

SECTION 3
FUNCTIONAL OPERATION
17
SECTION 3 –Functional Operation
Sequence of Operation
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. Turns Printer ON.
User Prepares Layout and Creates a Job
1. Selects the database and opens layout software such as Microsoft Word.
2. Creates a layout consisting of the variable data from the database using merge function.
3. Creates a layout using fixed information (such as return address) and adds graphics as required.
4. Saves layouts.
5. Initiates Print function through File menu.
6. Selects whether job has an Overlay or not through Printer Driver Properties menu.
7. Clicks Print button to print job.
Printing Job
1. Once a job is sent to Printer and downloading is complete, system signals
Interface Board to turn Main Motor ON at preset speed.
2. ON LINE key lights up and Drive Motor starts to run, causing Media Transport Belt under
Printheads to turn.
3. Press ENTER and Feed Clutch turns, causing two sets of Feed Rollers to turn and feed media.
4. After media travels 2.5", it covers Photosensor and lowers its output. This turns Feed Clutch OFF
and stops Feed Rollers. Forwarding Rollers, driven by Transport Belts, move media to Printheads.
The 2.5" distance between Feeder and Photosensor paired with clutch action creates a 2.5" gap
between mailing pieces. Gap allows media to feed reliably and the variable data sent by the PC to
be positioned for printing.

SECTION 3
FUNCTIONAL OPERATION
18
Printing
Print Engine consists of three stationary Printheads and a rolling Belt which position the media.
Two Circuit Boards control the Printheads.
Printer Functional Description
1. Photosensor located in media path between Feeder section and Printing section senses lead edge of
media and signals Print Engine on Main Processor Board that mailing piece has arrived for
printing. Feed Clutch remains disengaged as long as a mailing piece is in view of Photosensor.
2. When mailing piece uncovers Sensor, Clutch engages Feed Rollers and next piece of media starts
moving toward Printer section. At this time, Print Engine downloads next variable record from PC
and gets ready for printing.
3. This cycle repeats itself as long as there is media in Feeder.
4. Either cycle stops when Feeder runs out of media, operator stops the process, or no records remain
to be printed.
Printer Control Panel
1.
ON LINE key –Indicator lights when data is sent to Printer and printing is ready to
begin. Also takes Printer off line to access Menu mode.
2.
+ key –In Menu mode, this key scrolls to next selection.
3.
ENTER key –Starts and stops printing.
4.
FAULT Indicator –Lights when there is a problem with printing process.
5.
RESET key –Resets Printer to “standby” state.
6.
- key –In Menu mode, this key scrolls to previous selection.
7.
MENU key –Puts Printer into Menu mode to access operator functions.
8.
TEST PRINT key –Puts Printer in Test mode and prints a sample copy to check
Printer’s output.
9.
OPERATOR (LCD) DISPLAY –Shows Printer’s status including menus, prompts and
error messages.