AstroJet II Image System, ASF 3000 Vacuum Shuttle Feeder, FF 14 Friction Feeder Installation and Operating Manual
Below you will find brief information for Image System II, Vacuum Shuttle Feeder ASF 3000, Friction Feeder FF 14. The AstroJet Image System II is a professional addressing system that is designed to help you print your mailing labels with precision and speed. It is equipped with a variety of features that make it easy to use, including a simple control panel, a large LCD display, and a high-quality inkjet printer. The Image System II can be set up to print in automatic mode, which means that you can start printing just by clicking GO on the Control Panel and then pressing the ENTER key on the Printer. Or you can set it up to print in manual mode, which allows you to control the speed of the printer. The Image System II uses a vacuum shuttle feeder to feed the media, which allows it to handle a variety of media types, including folded media. The Image System II can handle pieces up to 1/2-inch thick.
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AstroJet
TM
IMAGE SYSTEM II
Professional Addressing System
INSTALLATION AND
OPERATING MANUAL
SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER,
OBSERVE SAFETY RULES WHEN OPERATING THE IMAGE SYSTEM II.
BEFORE USING THE SYSTEM, READ THIS MANUAL CAREFULLY AND FOLLOW THE
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 the machine is in use. Before clearing a jam, be sure machine mechanisms come to a stop.
Always turn off the machine before making adjustments, cleaning the machine, or performing any maintenance covered in this manual.
Always use the power cord supplied with the machine and plug it into a properly grounded, easily accessible wall outlet located near the machine. Failure to properly ground the machine can result in severe personal injury and/or fire.
Power cord and wall plug are the primary means of disconnecting the machine from the power supply.
DO NOT use an adapter plug on the line cord or wall outlet.
DO NOT remove the ground pin from the line cord.
DO NOT route the power cord over sharp edges or trap it between furniture.
Avoid using wall outlets controlled by wall switches or shared with other equipment.
Make sure there is no strain on the power cord caused by jamming between equipment, walls or furniture.
DO NOT remove Covers. Covers enclose hazardous parts that should 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 the 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.
Hewlett-Packard is a registered trademark of Hewlett-Packard Corporation.
Windows 98, Windows 2000, Windows ME, and Windows XP are registered trademarks of Microsoft Corporation.
IBM is a registered trademark of International Business Machines.
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, without permission in writing from the Publisher.
Table of Contents
SECTION 1 – Getting Acquainted
FF 14 Friction Feeder Control Panel
ASF 3000 Vacuum Shuttle Feeder Control Panel
SECTION 2 – Installing Image System II
Wiring and Connecting Image System II
Setting up FF-14 Friction Feeder
Setting up ASF 3000 Shuttle Feeder
Adjusting Image System II Base Media Guides
Installing Software on Computer
SECTION 3 – Operating System
Setting Up Image System II to Print a Job
SECTION 4 – Maintenance
Replacing the Sheet Separators on the Friction Feeder
Optional FF-14 Friction Feeder
Optional ASF-3000 Shuttle Feeder
TABLE OF CONTENTS
7
1
21
28
i
TABLE OF CONTENTS
SECTION 5 – Troubleshooting
Interface Communication Problems
APPENDIX A – Specifications
APPENDIX B – Supplies and Computer Requirements
INDEX
43
44
45
35
ii
NOTES
TABLE OF CONTENTS iii
SECTION 1
GETTING ACQUAINTED
SECTION 1 – Getting Acquainted
IMAGE SYSTEM II
1
ASF 3000 VACUUM SHUTTLE FEEDER – Vacuum Shuttle Feeder is shown.
Optional FF 14 Friction Feeder also available.
2 MAIN BASE UNIT – All controls, computer, and Printer are located here.
3
COMPUTER MONITOR SUPPORT
– Computer monitor, keyboard, and mouse are located on this support. Computer CPU is located in Main Base
Unit behind left front door.
4 IMAGE SYSTEM II PRINTER – Prints information on media.
5 DRYER BASE
– If system is so equipped, Infrared Dryer unit mounts here.
6 CONVEYOR STACKER – Media stacks on this conveyor after printing.
1
SECTION 1
GETTING ACQUAINTED
IMAGE SYSTEM II Control Panel
A Main Control
1
STOP – Shuts down entire machine. Must be turned in direction of arrows to reset system to restart.
2 POWER – When Stop button is reset, press this button to start system.
B Transporter Section Controls
3
AUTO/MANUAL
– Places Transporter in AUTO mode (Printer controls
transport speed) or MANUAL mode (Operator controls transport speed).
4 POWER
– Controls power to Transport unit.
5 VACUUM – Controls vacuum in transport.
6
SPEED
– Controls Transport speed when AUTO/MANUAL switch is in
MANUAL position.
C Dryer Section Controls
7
AUTO/MANUAL
– Used to place Dryer in AUTO (Printer controls Dryer
speed) or MANUAL mode (Operator controls Dryer speed.)
8 POWER – Controls power to Dryer unit.
9 BLOWER – Controls Blower in Dryer section.
10
SPEED
– Controls Dryer’s transport speed when AUTO/MANUAL switch is in MANUAL position.
D Conveyor Controls
11 POWER – Controls power to Conveyor unit.
12 SPEED
– Controls Conveyor speed.
2
FF 14 Friction Feeder Control Panel
SECTION 1
GETTING ACQUAINTED
1
5
SPEED – Used to vary Feeder speed in MANUAL mode to provide separation between pieces being printed. In AUTO mode, additional separation of pieces can be accomplished in Control Panel software.
2
3
CONTINUOUS FEED – When pressed, and Feed Select Switch is in
MANUAL position, Feeder feeds continuously.
SINGLE FEED – When pressed, and Feed Select Switch is in MANUAL position, permits Feeder to feed a single piece of media.
4 BATCH COUNTER – Resettable. Keeps track of pieces run on each job.
AUTO/MANUAL
– When Feed Select Switch is in MANUAL, operator can feed one or continuous pieces of media by pressing FEED Switches.
When in AUTO, Image System II controls Feeder through ENTER key on
Printer Control Panel if Feeder is connected to Printer.
3
SECTION 1
GETTING ACQUAINTED
ASF 3000 Vacuum Shuttle Feeder Control Panel
1 Resettable Counter – Keeps track of number of pieces run.
2 STOP Button
– Stops Feeder and locks out controls.
3
4
MAIN Power Button – When STOP switch is unlocked, pressing this button turns Feeder power ON.
JOG Button – When Main power is ON and Feeder Power switch is OFF, Jog button is used to feed material.
5
POWER Switch – In OFF position, permits operator to jog machine. When
ON, permits machine to run continuously.
6 VACUUM Switch – Turns Vacuum Pump ON.
7 SPEED Control – Controls Feeder speed.
4
SECTION 1
GETTING ACQUAINTED
Printer Control Panel
1
ON LINE key
– Indicator lights when data is sent to Image Blaster and it is ready to begin printing. Also turns Printer OFF LINE to access MENU Mode.
2 FAULT Indicator – Lights when there is a problem with printing process.
3 - Key – In MENU mode, scrolls to previous selection.
4 + Key – In MENU mode, scrolls to next selection.
5 ENTER key – Starts and stops printing.
6
7
MENU key
– Puts Printer into MENU mode to access various operator functions.
OPERATOR DISPLAY – Indicates Printer’s status including menus and error messages.
8 RESET Key – Resets Printer to "wait state".
9
TEST PRINT Key – Puts Printer into TEST mode and sends a sample copy t o check Printer’s output.
10
MEDIA THICKNESS Knob
– Adjusts height of Printheads to compensate for different media thicknesses.
5
6
SECTION 1
GETTING ACQUAINTED
NOTES
SECTION 2
INSTALLING THE IMAGE SYSTEM II
SECTION 2 – Installing Image System II
To install the system:
Choose a location for Image System II
Assemble Image System II
Connect components to power and the printer to computer
Install Inkjet Cartridges
Set up feed on feeder
Install Image System II software on computer
Choose a Location
Image System II should be placed at least 12 inches from any walls on a solid floor, not carpeting. Protect the Image System II from excessive heat, dust, and moisture – avoid placing it in direct sunlight. Below is a drawing of the complete Image System II with an
ASF-3000 Feeder showing the installation space required.
7
SECTION 2
INSTALLING THE IMAGING SYSTEM II
Assembling Image System II
Leveling Base Unit
Before beginning, decide where the System is to be installed. Make sure that adequate 220
VAC (4-wire, two 115V lines plus neutral and ground) are available. This machine must be connected to a dedicated line. If an Infrared Dryer is to be installed, it should also have its own dedicated 220 VAC Line.
Begin by placing Base Unit in position on a bare floor (Carpeting is not recommended). Place a level on the front plate of the Base Unit and level the machine using the four leveling feet.
Check the front to rear level of the Base by placing a level on the Transport Belts.
Attaching Feeder
Make sure that Image System II Printer is disconnected from the power source.
Remove the Covers from the Feeder, Main Base, and Dryer Cabinets.
Four screws attach Feeder Base to Main Base. Two screws attach Dryer Base to Main Base. To install ASF-3000 Vacuum
Shuttle Feeder to Main Base you must first install lower mounting bracket supplied to Feeder base.
NOTE: FF-14 Friction Feeder does not require lower mounting bracket.
8
Raise Feeder Stand so the four holes line up with the threaded holes in the Base Unit and install the four Allen head screws and washers.
Attaching Dryer Base
Raise Dryer Base until table on Dryer Base is even with table on Main Base Unit. Attach Dryer
Base to Main Base Unit at the top with two Allen head screws supplied.
Dryer Installation
If also installing a Dryer, it mounts between the two supports on the Dryer Base. (Installation
shown is typical.) Refer to information supplied with Dryer for assembly and operation.
SECTION 2
INSTALLING THE IMAGE SYSTEM II
9
SECTION 2
INSTALLING THE IMAGING SYSTEM II
Wiring and Connecting Image System II
Once System is assembled and leveled, the next step is to connect the various parts electrically. Two outlet boxes at the left rear of the Main Base unit provide power to the various parts of the System. One outlet box is marked SWITCHABLE and the other one is not marked. SWITCHABLE Outlet Box is wired to the safety circuit. Feeder is plugged into the box for power. Unmarked Outlet Box has power on it as long as the System is plugged into the power source. This Outlet Box is where the COMPUTER, PRINTER, MONITOR, and any other devices that have to remain powered during an Emergency Shutdown are plugged. If the System has the optional FF-14 Tabber, it can also be plugged into this box or directly into a separate wall outlet.
WARNING!
MAKE SURE SYSTEM IS DISCONNECTED FROM POWER SOURCE
BEFORE BEGINNING WIRING.
Remove all Covers from System (if not already done). Connect following cables in order:
1. Connect the two cables from Dryer Base to the two cables under Control Panel on front of Main Base Unit. Thinner wire is
Dryer Sensor connector and the other thicker wire is for power and control of
Dryer Base Motor and Cooling Fans.
2. Next connect Dryer Sensor to the plug at the rear of the Dryer and plug the 24 VAC Plug from the
Dryer into the 24VAC connector on the left rear of the Base Unit.
CAUTION
DO NOT ATTEMPT TO POWER DRYER UNIT
FROM IMAGE SYSTEM II BASE. DRYER
REQUIRES A SEPARATE CONNECTION.
10
SECTION 2
INSTALLING THE IMAGE SYSTEM II
3. Install computer CPU in Base Unit.
Computer Monitor, Keyboard and
Mouse are installed on Monitor
Stand of Base Unit. Two clamps provided to hold the monitor in place. CPU and Monitor should be plugged into the Non-Switchable
Outlet Box.
CAUTION
COMPUTER AND PRINTER SHOULD BE PLUGGED INTO UNMARKED
RECEPTACLE BOX PROVIDED IN BASE OF IMAGE SYSTEM II.
THIS RECEPTACLE BOX ALWAYS HAS POWER WHEN SYSTEM IS
PLUGGED INTO WALL OUTLET. USE ONLY POWER CORDS SUPPLIED.
4. Connections for the computer and System are on left-hand side of Printer. a. Connect parallel cable from computer to parallel port on Printer. b. Plug Printer Power Cord into Non-
Switchable Outlet Box, then into Printer. c. Connect cable at the top center of Base unit marked ENCODER to Printer
Encoder. d. Connect cable at the top center of Base unit marked INTERFACE to Printer
Interface Connector. e. Remove Jumper Plug from
INTERFACE connector on Shuttle
Feeder (not required on Friction
Feeder). Connect a cable from the
INTERFACE connector [3] on Feeder to FEEDER connection on Printer (required
on both Shuttle and Friction Feeders).
5. Route Power Cord from Feeder through oval hole on Base Unit right-hand side and plug Feeder into SWITCHABLE Outlet Box.
11
SECTION 2
INSTALLING THE IMAGING SYSTEM II
6. Remove Jumper Plug and connect a cable from the Safety Stop connector [1] on
Shuttle Feeder to Emergency Stop-Out connector [1] on left-hand side of Base Unit.
7. Remove Jumper Plug and connect second cable from Emergency Stop-Out connector
[2] on Shuttle Feeder to Safety Stop Connector [2] on right-hand side of Base Unit.
NOTE: Plug on Base R/H side marked [5] Emergency Stop-Out goes to Tabber
Safety Stop (if installed) and Plug on Base L/H side marked [5] Safety Stop goes to
Emergency Stop-Out on Tabber. Tabber should be plugged into Non-Switchable
Circuit Box in Base for power or into a separate 115 VAC wall outlet.
8. [3] Plug Interface is connected to Feed connector on Printer.
9. Conveyor is connected [4] Plug Conveyor for power and control.
12
SECTION 2
INSTALLING THE IMAGE SYSTEM II
Completing System Assembly
Remove packing blocks from Printheads (or installed Side Guides on Feeder (if not done). Check safety circuit on each parts of the system before operating for the first time.
WARNING!
FOR SAFETY, IT IS IMPORTANT THAT EMERGENCY STOP CIRCUIT IS
PROPERLY CONNECTED. ONCE CONNECTED, CHECK SAFETY CIRCUIT
OPERATION BEFORE OPERATING SYSTEM.
Install Inkjet Cartridges
Image System II can be configured with eight Inkjet Cartridges.
Install standard cartridges as follows:
1. Remove Inkjet Cartridge from packaging, take care not to touch copper contacts, metal plate, or tgold printhead. Remove protective tape from Printhead.
2.
3.
Release Latch Lever mounted on the Inkjet
Cartridge Holder.
With Cartridge’s
Printhead pointing down, slide Cartridge into tHolder and 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. (See diagram.)
5. Repeat Steps 1-4 above for remaining Cartridges.
NOTE: For optimum image quality during the run, refer to "Cleaning the Printhead”.
Ink in Cartridge may be harmful if swallowed.
Keep new and used cartridges out of reach of children.
Discard empty cartridges immediately.
13
SECTION 2
INSTALLING THE IMAGING SYSTEM II
Setting up FF-14 Friction Feeder
1. Release Separator Locking Lever located on operator’s side of
Feeder, raise Separators to "UP" and locked position. Move Side
Guides out to extreme open position. Place one piece of media in the center of Feed Table.
NOTE: There are four Separators on Feeder. Use two center
Separators for narrow media and all four
Separators for wide media.
Place media under the Separators and lower Separators so they rest on media.
2. Rotate Locking Lever up to lock Separators in place.
3. Adjust Side Guides to within 1/32inch of media and set Back Guide so media is raised approximately
1/2-inch and rests on curve of Back
Guide. When running 10 inch or longer or heavy media you may have to set Back Guide so it just touches back of media.
4. Release Forwarding Roller by moving Locking
Lever [A] in direction of arrow. Hand feed one piece of media into Printer. Adjust Side Guides and Belts on Printer to the media. Allow approximately 1/16-inch between media and Side
Guides. Adjust Media Sensor Assembly [B] so
Sensor is pointed straight down at media as it passes under it.
14
SECTION 2
INSTALLING THE IMAGE SYSTEM II
NOTE: Forwarding Roller Locking Lever is set in locked or down position when running media less than 1/4" thick. Forwarding Rollers should be locked in "UP" position when running media thicker than 1/4".
5. Turn Image System II ON. Place a piece of media under Printer. Use Height Adjustment
Knob to raise or lower Printer until you feel a slight drag when you pull on media.
NOTE: These are initial settings. It may be necessary to adjust MEDIA THICKNESS
Control to optimize print quality
6. To test feed media after set up, turn Feeder and Printer ON. Place AUTO/MANUAL
Selector Switch on Feeder to AUTO. Press TEST PRINT key on Printer, then press the
ENTER, to test feed media.
Setting up ASF 3000 Shuttle Feeder
1. Choose and Install Proper Vacuum Plate.
ASF 3000 Shuttle Feeder Kit contains four Vacuum Plates. Each one works best with a specific type of media. Refer to the chart below and select the plate for the media you will be feeding:
MEDIA
Single sheets of paper
Thin post card stock
Thick media up to 1/2"
Folded media
VACUUM PLATE
1
2
3*
4
NOTE: *Use P/N 28-105-45 Rear Pusher on media
1/4-inch or thicker to improve feeding.
Install Vacuum Plate: a Remove Philips screw holding Vacuum Plate to
Vacuum Arm. b Remove Plate. c Install new Plate, reinstall screw.
2. Adjust Forwarding Rollers to media. a Release Media Thickness/Separator Locking
Lever [A]. b Raise Roller Pressure Lever [B] to release pressure between Forwarding Rollers.
15
SECTION 2
INSTALLING THE IMAGING SYSTEM II c Place one piece of media under Forwarding
Rollers, then lower Roller Pressure Lever [B]. d Adjust the Media Thickness Knob [C] until you feel a slight drag on the media from the Rollers.
3. Adjust Sheet Separator: a Raise Sheet Separator using Separator
Adjustment Knob [D]. Place a second piece of media under Sheet Separator. b Adjust Sheet Separator Knob [D] so second sheet of paper is held firmly by Separator, but when it is removed, the sheet under it slides smoothly. c Use Thickness/Separator Locking Lever [A] to lock in settings.
4. Operating Shuttle Feeder: a Center media and adjust two Side Guides [1] to within 1/16-inch of media. b Lock Side Guide in place with Locking
Levers [2]. c Adjust Rear Guide [3] to within 1/16" of rear of media. Tighten two Locking
Knobs [4]. d Set Sheet Length Switch [11] to proper position for media length. (UP TO 13 IN for media less than 13"long or OVER 13
IN for media over 13" long.) e Turn STOP Button [5] clockwise to release switch. Press POWER Button [6] to start machine.
f Turn VACUUM Switch [9] ON and set SPEED to 1 or 2 [10].
16
SECTION 2
INSTALLING THE IMAGE SYSTEM II g Press and hold JOG Button [7] until one piece of media is fed. (This is to check your
setup and feeding of the media.) h Reset COUNTER to Zero (0) by pressing RED button next to Display. i Turn POWER Switch [8] ON to start continuous feeding.
NOTE: When Shuttle Feeder is connected to an Image System II Base Unit, Base Unit should be turned ON and operating. When ENTER is pressed, Feeder will start to feed if Power Switch is ON.
Shuttle Feeder Forwarding Roller Parallel Adjustment
Lever [F] is used to adjust parallel alignment of
Forwarding Rollers in cases where media skews.
Lower Forwarding Rollers are spring-loaded and as a result, this adjustment does not have to be performed for every setup. It should only be performed when Rollers are replaced.
1. Release Thickness/Separator Locking Lever
[A]. Then loosen Hex Screw [E].
2. Place two strips of 20-lb. paper under
Forwarding Rollers and adjust Media
Thickness Knob [C] until one of the strips has a slight drag in it.
3. Lock Lever [A] and adjust Lever [F] until drag on both sides is even, then tighten Hex
Screw [E].
Adjusting Image System II Base Media Guides
Before you can feed media, Media Guides and
Transport Belts on Base Unit must be adjusted to accommodate media.
1. Loosen Locking Knobs and move two Side
Guides to full open position.
2. Adjust Transport Belts so they support media.
Transport Belt Guides have a ring [A] on them that will assist you when moving them.
Turn Base Transport ON in Manual, then insert
17
SECTION 2
INSTALLING THE IMAGING SYSTEM II a rod of wood or metal [B] in hole in Guide. Move Guide with Belt in direction required to place the Belt.
WARNING!
BELTS HAVE TO BE ADJUSTED WITH MACHINE RUNNING.
DO NOT TOUCH ANY MOVING PARTS DURING THIS PROCESS.
3. Loosen Side Guide Locking Knobs [C] and place Side
Guides to within 1/16" of media.
4. Adjust Media Thickness Guide [D] by loosening two screws on each end of Side
Guides and lower Ball Guide Assembly so it just rests on media.
5. Adjust two straps between Side Guides to rest on top of media. Loosen locking screws [E] to move straps from side to side. Additional adjustment for pressure of straps on media can be obtained by loosening strap-locking screws [F] and raising or lowering them.
18
SECTION 2
INSTALLING THE IMAGE SYSTEM II
6. Exit Rollers mounted on Dryer section should also be adjusted. Loosen locking screw [G] and position Rollers so they run on media outside of printing area.
Rollers can be adjusted for different media thicknesses by rotating clamp on mounting bar.
Installing Software on Computer
System operates on Windows
TM
compatible Printer Drivers.
Types of Software
Image System II can operate on one of two types of software. Refer to the Software Manual supplied with the system for installation and operating instructions.
AstroJet Professional Software
The AstroJet Professional Software is an integrated package that contains a Layout Editor and a
Printer Control Panel.
1. The Layout Editor is used to create the piece.
2. The Printer Control Software is used to print the piece and control the Printer.
3. The printing is done through the Parallel port of the computer.
PCL Driver and Software
1. The PCL Printer Driver sends the piece as laid out on your application to the Printer.
2. The Printer Driver can connect the Printer to the computer with either the Parallel port or the USB port.
3. The software supplied with the PCL version of the system is AstroPrint. It is layout software that you can import your database into and print both fixed and variable data. It can also print graphics.
4. The PCL Driver can also be used with all of the popular brands of mailing software available.
19
20
SECTION 2
INSTALLING THE IMAGING SYSTEM II
NOTES
SECTION 3
OPERATING THE IMAGING SYSTEM II
SECTION 3 – Operating System
Setting Up Image System II to Print a Job
The preferred method of running the Image System II is in AUTOMATIC mode. When set up to run in Automatic mode, clicking GO on Control Panel and then pressing ENTER Key on Printer will start the media feeding and cause Printer to print. Refer to Section 1 – Getting
Acquainted for location of switches referred to below.
To set up the Image System II to print in Automatic Mode, set switches and dials as follows:
1. Make sure that Emergency Stop Switches have been released. System cannot be turned on if any Emergency Stop Switches are depressed.
2. Turn Printer Power Switch ON, and start the computer.
3. On the System Control Panel, set the Transporter Mode Select Switch to AUTO and the
Dryer Mode Select Switch to AUTO.
4. If using the Friction Feeder, set the Select Switch to AUTO and turn the unit ON. Then press the CONTINUOUS Feed Switch. When you are ready to print, press the ENTER key on the Printer to start the Feeder. If you have a Shuttle Feeder attached to the system, go to Step 5.
5. When using the Shuttle Feeder, first make sure that the Emergency Stop Switch is released, and then press the POWER Switch to turn the unit ON. To feed from the unit, both the POWER Switch and the VACUUM Switch must be ON. When you are ready to print, press the ENTER key on the Printer to start the Feeder.
6. Turn POWER and VACUUM Switches ON for the Transporter and Dryer on the System
Control Panel. Also, turn the POWER Switch ON for the Conveyor if the optional
Conveyor is installed. The Conveyor will start automatically, but you must adjust the speed manually for the best stacking of the media.
NOTE: When the Image System II is set up for automatic operation, the speed of the system is selected by the resolution of the print. To run at other speeds, select the MANUAL Modes for the Transporter and Dryer. You cannot run the system faster than the maximum speed for the resolution selected.
Starting Up the Image System II
If the Image System II has been sitting idle for a period, purge the Printheads before beginning to run a job. This can be done from the Printer LCD Display Panel. Press the
MENU key. Then use the “+” or “–” keys to scroll to “PURGE”: then press ENTER. Run a few pieces, then press ENTER again to stop the purge. Check that the pattern run on the media is even, without any blank areas or white streaks. If the pattern is OK, then send the job and start printing. Any time the Image System II sits idle for a while, the purge routine should be run before running the job.
21
SECTION 3
OPERATING THE IMAGING SYSTEM II
Printing a Test Print
A Test Print is built into the Printer. Press TEST PRINT key. Display indicates it is working.
Then Display changes to "Press Enter Key" to print. Press ENTER key to start media feeding and Printer prints the standard test job.
To print a sample of your job, refer to the Printer Operator Manual for instructions.
Printing the Job
Click on the GO button to begin printing. Image System II begins by rendering the fonts and logos, then downloading them to the Printer. Depending on the complexity of the page, this process may take up to a few minutes. Once a font or logo is rendered, the Image System II can call it up from this folder for reuse the next time a job that uses that particular font style or logo is run. When the Image System II starts, simply press the ENTER key on the Printer to start the system.
Monitoring the Job
Stop the Image System II by pressing the ENTER key on the Printer or by clicking on STOP in the AstroJet Software Control Panel without affecting the job. The Printer will resume printing at exactly the same point in the database when it is restarted.
NOTE: Pressing any RED Emergency Stop Switch will stop entire system immediately .
Printing a Test Print
Pressthe TEST PRINT key on the Printer Control Panel to print the built-in Test Print. The
Test Print has been preloaded into the Printer’s memory. It will print information from all the cartridges installed on the Printer. I you wish to print a test copy of the job you are printing, then use "Printing a Test Print" above.
Monitoring the Job
The AstroJet Image System II can be stopped by pressing the ENTER key on the Printer or by clicking on STOP in the AstroJet Software Control Panel without affecting the job. The
Printer will resume printing at exactly the same point in the database when it is restarted.
22
SECTION 3
OPERATING THE IMAGING SYSTEM II
Printer Controls
When you first turn the Printer ON, the ON LINE key light blinks. Printer’s Display shows
“ Printer Offline / Enter for Paper Feed”. The TEST key light is OFF. In this mode, pressing the ENTER key will start the paper feeding, but no printing will take place.
To print, you must put the Printer ON LINE. When you do, the Display changes to “Printer
Online / Waiting for Data”. In this mode, when you send a job, the Printer will be ready to print when the ENTER key is pressed.
The following is a description of the operation of the Printer’s various menu options that let you customize the operation of the Printer. 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:
TEST Key
Pressing the TEST key places the Printer in Test Print mode. “Working” appears in the lower half of the Display and then changes to “Enter to feed”. Pressing the ENTER key will start the printing process and print the Test Print. To stop feeding, press ENTER again.
NOTE: If you have chosen to have the Printer start automatically (see the MENU Key
below) the Printer will start printing the test print once it is loaded without your having to press the ENTER key. In this case, pressing the ENTER key stops the paper feed.
To exit the Test Print mode, press the TEST key again and Printer returns to its ready state.
Pressing and holding the TEST key causes the Printer to enter the “Service Menu” where the various functions of the Printer can be tested. To exit the “Service Menu,” press the TEST key a second time. The Service Menu is primarily used by service to diagnose problems should they occur. You can use the “+” or “-” keys to scroll through the menu. Pressing the ENTER key will test the function.
To check the Ink Cartridges ink levels when you enter the Service Menu, press the “-” key and amount of ink remaining appears as a percentage in the lower half of the Display window.
MENU Key
Used to access special features built into the Printer and to customize the operation of the Printer.
Basic features are accessed by pressing the MENU key. Use the “+” or “-” keys to access the features. Features available under this mode of operation are as follows:
NOTE: If the ONLINE key is ON, you cannot enter Menu mode. First take the machine
"Off Line" by pressing the ONLINE key.
Media Thickness Setup – The first item to appear in the Display is the “Media Thickness
Setup” (if Printer is equipped with an Automatic Media Thickness Control). Use this feature to preset the Printhead height for various media thicknesses.
23
SECTION 3
OPERATING THE IMAGING SYSTEM II
Press Enter to Purge – "Purge" is useful in cleaing Printhead Nozzles when the machine has been sitting idle. To activate Purge, press ENTER to feed one piece of media. To purge the Printheads additional times, press ENTER for each additional purge.
NOTE: Printer will only purge one piece each time you press ENTER. For additional purges, press ENTER again for each subsequent purge.
Clear Batch Counter – Pressing ENTER clears the number in the upper right hand corner of the Display. Resetting the Counter is usually performed at the start of each job. Turning the Printer OFF will not reset this Counter.
Purge First Piece – Turning the feature ON causes the Printer to send one purge pattern on the first piece. After the purge is completed, the next piece will be have the first record of your database. Once this is turned ON, it will remain ON even if the Printer is turned OFF.
Address Recovery – In event of a jam in the Printer you can recover up to 10 pieces by pressing the MENU key, then stepping to “Address Recovery”. Then press ENTER.
“Enter: Recover 1 Piece” appears. Use the “+” key to select the number of pieces to reprint
(1-10), then press ENTER again to start the printing process. Once the pieces are printed, press the ONLINE key and then ENTER to resume printing the job.
Print Enhancement – Pressing the “+” or “-” keys brings Print Enhancement up in the display. Print Enhancement is used when printing to ensure that the Printhead Nozzles stay open and prevent the loss of descenders on letters such as “y” or “q” and accent marks that do not appear in every address. Pressing ENTER turns this function ON or OFF. Function remains as changed until the operator changes it again. Turning the Printer ON and OFF will not affect the setting.
NOTE: Print Enhancement feature times out after 100 seconds if no media is going through the Printer. Once media starts printing, it will restart.
Automatic Feed – Turning the feature ON causes the Printer to start feeding once the job is sent. If the ONLINE key is ON, the Printer will start feeding and printing automatically. If you prefer to press the ENTER key to start the printing process, turn this feature OFF.
Turning the machine ON or OFF will not affect your selection.
Installing New Printheads – The Printer is capable of telling you when a Printhead is running low on ink. To use this feature, press the MENU key. Then use the “+” or “-” key to highlight “Enter when head (n) is filled”. Press ENTER and install a new Cartridge.
Repeat for each Cartridge you install. When ENTER is pressed, Display changes to “Head
(n) has a new cartridge”. To check Cartridge ink levels, press and hold the TEST PRINT key until “Service Menu” appears. Use the “+” or “-” keys to scroll to “Service Menu: Ink
Levels, 100%100%100%”. This will show how much ink remains in the Cartridge.
NOTE: Feature only works if Cartridges remain in original head where they were installed.
If you swap Cartridges from one head to another, levels will not be accurate.
24
SECTION 3
OPERATING THE IMAGING SYSTEM II
A second set of Menus is available in the Display. To activate, press and hold MENU key until
“Setup Menu” appears. Step through these items with the “+” or “-” keys.
Total Count – Displays total number of prints that have passed through the Printer.
Non-resettable.
BIOS Version – Press the “+” key to display current BIOS version.
Bulk Ink – No provisions are made to install larger cartridges.
+ / - Key
Used to step through the options in various Menu Modes.
ON LINE Key
If ON LINE key is ON, Display shows “Printer Online / Waiting for Data” and light is lit. This means the Printer is ready to print the job when it is sent. To have the Printer start printing immediately when the job is sent, the Automatic Feed feature must be turned ON. If the ON
LINE key is OFF, Display shows “Printer Offline / ENTER for Paper Feed”. In this condition the machine can feed paper. This is useful for setting up the Feeder.
NOTE: If the Printer is Off Line and you send a job, the Display shows “Printer Offline /
Data Ready to Print”. To print, first press the ON LINE key to put the Printer On Line. If you sent data and the Printer is set up not to start feeding automatically and the ON LINE
key is lit, then Display will show “Printer Online / ENTER to Start Feed”.
ENTER Key
Used to start the Printer printing when it is On Line and the Automatic Feed is turned OFF.
Additionally, when the Printer is placed in any of the Menu Modes, the ENTER key is used to choose the options available.
RESET Key
Used to clear the Printer's memory and return it to the “wait state”. This key only functions if the
Printer is Off Line.
Purge While Printing
To Purge in the middle of a job:
Press ONLINE key to pause current job.
Press MENU key, then step to “Press Enter to Purge”.
Press ENTER to start Purge. Press ENTER again to stop Purge.
Press ONLINE key, then ENTER to get back to normal printing.
Note. If a paper jam occurs during the purge; after purging, use "Address Recovery" to get back to normal printing. Otherwise you will lose records.
25
SECTION 3
OPERATING THE IMAGING SYSTEM II
Types of Media
Image System II prints 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 determine performance levels before beginning the job.
Coated and plastic types of paper do not easily absorb ink and smearing may occur. Print may appear fuzzy on very porous paper. Another cause of fuzzy printouts is excessive buildup of dust within the machine, or if the Printhead is too far away from the media. Be aware, that when printing in the High Quality mode, drying time for the ink is longer than in the other modes. In addition, when humidity is high, drying time is increased.
Media Thickness
The Image System II handles pieces up to 1/2-inch thick (0. 5") if it is equipped with the
Vacuum Shuttle Feeder. All folds must be crisp and even.
CAUTION
DO NOT USE STAPLED PIECES IN THE IMAGE SYSTEM II.
DO NOT USE PAPER- CLIPPED PIECES IN THE IMAGE SYSTEM II.
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 IMPROPER USE.
USPS DOES NOT ACCEPT THIS TYPE OF MAIL FOR ITS
AUTOMATED EQUIPMENT.
Databases
The Image System II software is capable of handling many types of databases including .TXT,
.CSV, Microsoft Access. MDB, 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 Image
System II software to CSV files. In addition, whenever you update a file the Image System II
Software will reconvert and re-index it the next time you open it if you place the updated files in the Image System II Database folder in the software.
26
NOTES
SECTION 3
OPERATING THE IMAGING SYSTEM II
27
SECTION 4
MAINTENANCE
SECTION 4 – Maintenance
This section discusses how to care for the Inkjet Cartridges, clear paper jams, replace Sheet
Separators, and perform routine operator maintenance to the Image System II Printer.
The Inkjet Cartridges
Image System II 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.
Approximate life of the HP 51645A Inkjet Cartridges based on three lines of 20 characters at 10point size per address is:
AstroJet Version:
High Quality
Standard Quality
Draft Quality
50,000 addresses
100,000 addresses
200,000 addresses
PCL Version:
600 x 600 DPI
300 x 600 DPI
200 x 600 DPI
150 x 600 DPI
50,000 addresses
100,000 addresses
150,000 addresses
200,000 addresses
NOTE: These figures can vary depending on the font selected. The Bulk Ink
Cartridge will print approximately 10 times the number of addresses as a
Standard Inkjet Cartridge.
To Replace Inkjet Cartridges:
1. Raise the Latch Lever to release the Cartridge, then pull Cartridge up and out of Holder.
2. Remove new Inkjet Cartridge from packaging. Take care not to touch copper contacts, metal plate, or gold printhead. Remove protective tape from Printhead.
3. With Cartridge’s Printhead pointing down, slide Cartridge into Holder and push down and toward the contacts in Holder.
4.
Make sure Cartridge is seated in Holder, then close Latch Lever to secure the Cartridge.
DO NOT force Latch Lever into place.
5. Repeat Steps 1-4 above for the remaining Inkjet Cartridges.
28
SECTION 4
MAINTENANCE
CAUTION
NEVER SHAKE, DROP, OR HIT CARTRIDGE AGAINST PALM OF YOUR
HAND OR ANY OTHER HARD SURFACE. SHAKING PRINT CARTRIDGE
DOES NOT “MIX” INK AND HITTING CARTRIDGE AGAINST A HARD
SURFACE DOES NOT CLEAR NOZZLES. BOTH ACTIONS HURT PRINT
QUALITY BECAUSE THEY ALLOW BUBBLES TO FORM NEAR INK
FIRING CHAMBERS. THESE BUBBLES PREVENT NOZZLES FROM
FIRING, CAUSING WHITE STREAKS IN PRINT IMAGE.
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 – Less than 2 days or less than 1 day in a hot and dry environment.
Long-term storage – 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. The next time that the Printer 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 Standard Cartridges in a sealable plastic container with a damp sponge or towel to maintain humidity and prevent the Printhead from drying out. When the Cartridges are ready to be used again, the Printhead will need to be cleaned.
Disposal
Cartridges may be disposed of in a normal manner.
In case of an ink spill, use soap and water to clean up any problem areas.
Abrasive soap works well in removing ink from your hands.
Cleaning the Printhead
To maintain good print quality it is important that the Printheads are kept clean. During the printing process ink spray, paper fibers, and dust can cause a build-up on the Printheads. This build-up will eventually degrade the print quality. If you begin to notice problems with the quality of the print, or to just prevent a build-up from occurring, wipe the Printhead with a wet fiberless cloth.
29
SECTION 4
MAINTENANCE
Cloth should be:
Soft
Fiberless
Cloth should not be:
Abrasive
Made of small fibers
Moistened with water
(Distilled is best but tap works)
Dry or contain chemical additives
Wipe slowly across the long-axis with the Printhead facing down (as shown). Do not apply excessive force, as this could scratch the Nozzle surface.
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 Image System II Printer. It can be accessed from the LCD Panel on the Image System II Printer. If this does not solve the problem, proceed as follows:
1. Wipe Printhead with a wet cloth as described in "Cleaning the Printhead" above.
2. Perform Purge from the Image System II Printer Display Panel.
3. Wipe Printhead again with a moist cloth.
NOTE: For more information, refer to "Troubleshooting Printheads" in Section 6 –
Troubleshooting Guide.
Jams in the Printer
If a jam occurs, STOP the Printer.
Missed addresses can be recovered at the computer from the Control Panel by stepping back to the place in the job where the jam occurred. No data will be lost.
Some possible reasons for jamming are:
1. Feeding more than one piece of media.
2. Damaged media, such a dog-eared (turned-down corners).
3. Media that is not stiff enough and may not be usable. Media that meets Postal stiffness requirements for automated feeding is acceptable in the Image System II.
4. Envelopes caught under the flap of another envelope or stuck to one another.
30
SECTION 4
MAINTENANCE
Removing Jammed Media
The Printer is equipped with a hinge device that permits it to be swung in the UP position to remove any jammed media. First turn the system OFF by pressing one of the STOP buttons.
To release the Printer, press down on the Grab Handle and release the two Latches on the lefthand side that lock the Printer in place. Then raise the Printer using the Grab Handle.
Refer to the appropriate Printer Operating Manual for job restart information.
Replacing the Sheet Separators on the Friction Feeder
Sheet Separators on the Friction Feeder insure separation of the pieces as they are being fed.
They wear and must be replaced periodically. If you experience double sheet feeding and cannot adjust the Separators to prevent it, they should be replaced.
Replacing the Sheet Separators is not difficult:
1. Turn System OFF and unplug it from the power source.
2. Release the Separator Locking Lever and move the
Media Side Guides to maximum open position.
3. Lower the Separators so they touch the Feed Roller.
4. Remove screw [A] and Separator Support [B]. Then remove Separator [C] by prying it out of the Holder.
5. Install a new Separator in place and reinstall the
Separator Support and screw.
Cleaning
Image System II
WARNING!
IMAGE SYSTEM II PRINTER IS A PRECISION MACHINE THAT SHOULD
BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE.
BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT MACHINE
FROM ITS POWER SOURCE!
System 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. Unplug the system from the power receptacle before removing the covers.
Internal areas – Best cleaned with a vacuum that has a soft brush attachment to help loosen the dust particles. Take care not to damage the PC boards or electrical wiring.
Exterior – May be cleaned with any standard non-abrasive household cleaner that does not contain plastic-harming solvents.
31
SECTION 4
MAINTENANCE
CAUTION
NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE IMAGE
SYSTEM II PRINTER. EXCESS LIQUID COULD HARM ELECTRONIC PARTS.
ALWAYS DAMPEN A RAG WITH THE CLEANER AND APPLY IT TO THE
PARTS TO BE CLEANED.
Cleaning the Media Sensor
Periodically check the Media Sensor [A] located on the Printer. Sensor is self-contained in that the light source and the Sensor are both in the
Assembly. Directly below the Sensor mounted on the Base Table is a reflective strip. Reflective strip [B] reflects light from the Sensor back to the Sensor when no media is present. As media passes under the Sensor, the reflection from the media tells the Printer it is time to print.
Sensor and light source should be kept clean and free of dust. Reflective strip should be kept clean of dust and dirt.
Sensor can be cleaned with a Q-tip by gently dusting it. Reflective strip can be cleaned with a mild soap solution on a damp cloth. Should the reflective strip become scratched or worn it should be replaced, as the system cannot function properly without it.
Optional FF-14 Friction Feeder
Cleaning Sensors
Two Sensors on FF-14 should be kept clean. Media Sensor [A] is located under Exit Guide Rollers (as shown). Jam Sensor [B] is located on Jam Sensor Support. Use a Q-tip to clean Sensor.
CAUTION
DO NOT USE SOLVENTS OR
ABRASIVES TO CLEAN THE SENSORS.
32
SECTION 4
MAINTENANCE
Optional ASF-3000 Shuttle Feeder
Cleaning Media Sensor
Periodically check the Media Sensor located just below the two large Forwarding Rollers. The Sensor should be clean and free of accumulated paper dust. Use a vacuum with a soft brush attachment or dry compressed air to remove the dust.
Cleaning Feed Rollers
Feed Rollers can become glazed with paper lint and ink from media. They should be regularly cleaned with a mild abrasive household cleaner on a damp cloth.
Avoid using solvents on Rubber Rollers.
Jar Filter
Location: Mounted on pump located in base of Shuttle Feeder.
WARNING!
JAR IS GLASS. TAKE PROPER PRECAUTIONS TO GUARD
AGAINST FRAGMENTING OR BREAKING THE GLASS.
CAUTION
GLASS JAR CAN EXPLODE IF SUBJECTED TO MORE THAN
5 PSI/35 BAR.
Cleaning: Jar and felt filter should be cleaned at least once a month
(after every 100 hours of operation). Unscrew and remove any debris from within the Jar. Use a compressed air hose to clean the felt Filter.
Then reinstall Jar.
33
SECTION 4
MAINTENANCE
Cleaning Vacuum Pump Filters
Vacuum Shuttle Feeder is equipped with an
Oilless Vacuum Pump. It does not require lubrication, however it does require cleaning.
1. Remove the two Filter Assemblies in the front of the Pump and brush the Filters with a stiff brush regularly.
WARNING!
CHECK VACUUM PUMP AT LEAST
ONCE A MONTH. FAILURE TO DO SO
CAN AFFECT PERFORMANCE OR
EVEN CAUSE PUMP OVERHEATING
AND FAILURE.
CAUTION
THE VACUUM PUMP IN THE SHUTTLE
FEEDER IS AN OILLESS PUMP.
DO NOT ATTEMPT TO PUT OIL OF
ANY KIND IN THE PUMP!
34
SECTION 5
TROUBLESHOOTING
SECTION 5 – Troubleshooting
This section is arranged first by the condition that might occur, and then by possible problems, their cause and recommended solutions.
WARNING!
DO NOT REMOVE ANY COVERS FROM IMAGE SYSTEM II
HIGH VOLTAGES PRESENT BEHIND COVERS!
Power Problems
CONDITION
Power ON, nothing happens.
PROBLEM
No power to
Printer or Base.
SOLUTION
Check that power cord is plugged in.
Check that power outlet is live.
Check fuses on power supply PC board.
(Requires disassembly)
Bad controller PC board
Bad power supply
Interface Communication Problems
CONDITION
Printer does not respond to software.
PROBLEM
Connection problems.
Printer not responding to software
Poor connection between
Printer and computer.
SOLUTION
Check that port is communicating with Printer by using another parallel or
USB cable on PCL version, replace cable.
If port cannot communicate using another parallel or USB cable, check Printer.
If port cannot communicate using another parallel or USB cable and Printer is OK, check parallel or USB port.
Check cable connection to see if any pins are bent or missing. If so replace cable.
Turn Printer OFF, then ON.
Check connections.
35
SECTION 5
TROUBLESHOOTING
LCD Display Problems
CONDITION
No LCD display.
LCD shows solid line of characters or garbage.
LCD displays solid black line or lines.
PROBLEM
Power not ON.
Contrast Pot broken or maladjusted.
Broken solder joint on
Contrast Pot.
Power supply
Static electricity
Bad power supply.
No firmware (BIOS).
Bad processor PC board.
SOLUTION
Turn power switch ON.
If still no display, see
"Power Problems".
Adjust Pot or replace display
PC board.
Repair or replace Display
PC board.
Check voltages and inspect power supply connections to processor PC board.
Turn Printer OFF, then ON
Check all voltages
Install firmware
Replace processor PC board.
Feeding Problems
CONDITION
Intermittent feeding
PROBLEM
Feed Ramp not used
Side Guides set improperly.
Dirty Feed Rollers.
Paper stuck together.
Bad or dirty Sensor.
Uneven mail piece.
Multiple feeds
Multiple feeds continued
Separator gap not set properly.
Sensor bad or dirty.
Media stuck together.
Side Guides too close to media.
Brake misadjusted.
SOLUTION
Feed Ramp adds a slope to 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 in Printer.
Clean Sensor with compressed air or replace it.
Tap inserts to front of envelopes and retry.
Adjust 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).
36
SECTION 5
TROUBLESHOOTING
CONDITION
Failure to feed
Jams
Jams continued
PROBLEM
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.
Printhead adjustment too low.
Paper path obstruction.
Paper not loaded properly.
Feed Ramp not used properly.
Separators improperly adjusted.
Media curled or bent.
Bad or dirty Sensor.
Worn Separator Tip.
Printhead adjusted too low.
Conveyor tape(s) under
Printhead broken.
SOLUTION
Readjust Side Guides.
Check that power button is ON and power cord is plugged in.
Adjust Separator to media thickness.
Adjust Separator to media thickness.
Maximum thickness is 1/4" or 0.125"
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 Motor circuit breaker or replace Motor.
See "Power Problems" in this
Section.
Adjust Printhead height to accommodate media thickness.
Clear jam and remove pieces remaining under Printhead.
Instruct operator in proper loading of media.
Set Feed Ramp.
Adjust Separators to media thickness.
Uncurl media.
Clean or replace Sensor.
Replace Separator Tip.
Raise Printhead
Replace tapes.
37
SECTION 5
TROUBLESHOOTING
Print Placement Problems
CONDITION
Print too close to leading or trailing edge of media
Print too high or low on media
Address prints upside down on media
Address too close to center of media
Address printing partially off media
PROBLEM SOLUTION
Size of media not set correctly in Layout.
Bad or dirty Sensor.
Feed Ramp not used properly.
Printheads set incorrectly.
Physical location of
Printheads do not match layout template.
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.
Remember there is a 1 5/16" space that is always blank between Head 4 and 5 and the Head 1, 2, and 3 bank.
Adjust Media Guides or
Printheads.
Use “0” reference point in center of scale to help you align print on media.
Layout and/or stock direction incorrect.
Chosen media size in layout is too small.
Physical location of
Printheads do not match layout template.
Feed Ramp not set properly.
Chosen media size in layout is too large.
Physical location of
Printheads do not match layout template.
Feed Ramp not set properly.
Change direction from
Normal to Inverted or
Inverted to Normal in
Properties of Driver.
Set correct media width size in layout.
Check image on layout screen, adjust Media Guide or Printhead.
Adjust Feed Ramp.
Set correct size in Layout
Check image on layout screen, adjust Media Guide or Printhead.
Adjust Feed Ramp.
38
SECTION 5
TROUBLESHOOTING
Print Content Incorrect
CONDITION
Information being printed is wrong, incomplete, or garbage
Barcode does not print
Unwanted BOLD, Italic, or Underlined type
Not all addresses in database print
Data is being lost
Graphics or text have a white line through them
PROBLEM
Poor cable connections.
Interface problem.
Corrupted database file.
Wrong font selected.
No zip code in database.
Barcode not enabled.
Turned on in layout.
SOLUTION
Check parallel cable is securely fastened at both ends. Cable does not exceed 6' in length.
Printers internal Parallel or USB cable in good condition.
Check Printer set-up at computer.
Use another database file.
If using a combined field barcode choose USPS barcode font.
Put zip code field in database or use another database.
Enable barcode.
Open layout and change type style.
Start new job and select entire database.
Only some addresses in database have been selected to print.
Database problem.
Parallel or USB cable connection loose.
Graphic or text is set between junction of two
Printheads.
Check database program.
Reconnect.
Move copy or adjust
Printheads.
Software Problems
Refer to the manual for the application software being used.
39
SECTION 5
TROUBLESHOOTING
Print Quality Problems
CONDITION
Black streaks in text
Cartridge will not print
White streaks in text or graphics
Extra lines; losing data
Improper output (address information out of order, miss-feeding, etc.)
Media jams
No communication
Not printing on media
Print too light or missing character dots
PROBLEM
Lint or paper dust on
Printhead.
Sheet is blank even after it has gone underneath Cartridge(s).
Lint or dust blocking
Printhead holes.
Poor contact between
Printhead and Printhead
Holder.
Database problem.
Wrong interface settings.
Static electricity.
Dirty media Sensor.
Double feeding.
Media is curled or bent.
Media is too thin.
Improper cabling / connector.
Unit not receiving power.
Media not positioned properly.
Clogged or dirty Printheads
Running out of ink.
SOLUTION
Clean Cartridge Nozzles with clean lint-free cloth moistened with distilled water.
Check to make sure tape is off Printhead.
Remove and reinsert
Cartridge into Carriage
Holder.
Install new Print Cartridge.
Clean Cartridge Nozzles with clean lint-free cloth moistened with distilled water.
Clean interconnects.
Remove and reinsert
Cartridge into Holder.
Insert a new Print Cartridge.
Check data in database program.
Check software or database on PC.
Close AstroJet Control Panel software, the turn Printer
OFF, then ON.
Clean Media Sensor.
Adjust Sheet Separators on Feeder.
Uncurl media.
Media must be at least
0.008".
Use proper cable
(see Operator Manual).
Check plug connections,
ON/OFF switch and fuse on back panel
(see Operator Manual).
Adjust Printhead vertically.
Adjust margin setting in
Layout software.
Purge or clean Cartridges.
Replace Inkjet Cartridges.
40
SECTION 5
TROUBLESHOOTING
CONDITION
Blurry address
PROBLEM
Image is not sharp.
SOLUTION
Printhead gap too high.
Adjust Printhead closer to the media.
Split line of type
Uneven split line of type
Line of type is placed across two Printheads.
Some but not all of a line of type across two Printheads matches up.
Reposition text in layout so it does not print across two
Printheads.
Adjust positioning of two
Printheads in relation to each other using Head Alignment
Tool in Properties window of Driver.
Reposition text in layout so it does not print across two
Printheads.
Check Sheet Separator adjustment. Separators should just touch media.
Check that Printhead is set at proper height.
A Printhead set too high causes slippage in media as it passes under Heads.
WARNING!
DO NOT REMOVE ANY COVERS FROM IMAGE SYSTEM II
HIGH VOLTAGES PRESENT BEHIND COVERS!
41
SECTION 5
TROUBLESHOOTING
42
NOTES
SECTION 5
TROUBLESHOOTING
APPENDIX A – Specifications
PRINT QUALITY
(Dots Per Inch)
PRINT SPEED Up to 26,000 #10 Envelopes per hour
IMAGE SYSTEM AREA 3 or 4 inches depending on the printer version
MEDIA SIZES
600 x 600 dpi
600 x 300 dpi
600 x 200 dpi*
600 x 150 dpi
Maximum: 17" long x 13.5" wide up to 1/2" thick
Minimum: 5" long x 3" wide up to 1/2" thick
HP 51645A Inkjet Cartridge PRINT MECHANISM
NUMBER OF
CARTRIDGES
GRAPHICS AND
LOGOS
SOFTWARE AND
FONTS
PRINT COLORS
INK
OPERATOR DISPLAY
OPTIONS (LCD)
PC INTERFACE
DIMENSIONS
ELECTRICAL
6 or 8 Cartridges
Allows printing of graphics, logos, and pictures.
Windows
TM
compatible Printer Drivers
All Windows True-Type fonts coated stock
Standard Black, Versatile Black, and Spot Colors
Water-based, may require drying assistance for
Counter, Stop on Break, Print Enhancement,
Print Resolution, Purge, BIOS Version
Parallel Cable or USB
123" W x 35" D** x 70" H
220 VAC, 50/60 Hz
** Does not include Conveyor
The information (electrical and physical dimensions, etc.) on the IMAGE SYSTEM II is presented here for your reference. Specifications are subject to change without notice.
43
APPENDIX B – Supplies and Computer Requirements
Supply items and optional hardware are available from your Astro Machine Dealer.
Supplies
Black Inkjet Cartridge
Yellow Inkjet Cartridge
Red Inkjet Cartridge
Green Inkjet Cartridge
Blue Inkjet Cartridge
Versatile Black
Black Image Quake
HP 51645A
HPC6173A
HPC6168A
HPC6169A
HPC6170A
HPC8842A
IQ2392
Computer Requirements
1. An IBM or Compatible Pentium 100 Megahertz PC or better.
2. Windows 98, 2000, or XP installed.
3. A minimum of 20 Megabytes of free hard disk space.
4. At least 32 Megabytes of RAM. (64 Megabytes for Windows 2000 and XP)
5. A 2X CD ROM or better.
6. An 800 x 600 SAGA Monitor or better.
7. Parallel (Centronics) printer cable, no longer than 6 feet or a USB cable (for
PCL version only.
8. The Parallel Port must be set to the PEP (Enhanced Parallel Port) setting in the COMES of the computer.
44
INDEX
INDEX
- Key, Printer ................................................ 5, 25
+ Key, Printer ............................................... 5, 25
A
ASF-3000 Shuttle Feeder ................................ 1
Cleaning ....................................................... 33
Control Panel ................................................. 4
Counter, Resettable ....................................... 4
Feed Rollers, Cleaning ................................. 33
Forwarding Roller, Adjust ............................. 17
Jar Filter, Cleaning ....................................... 33
Jog Button ...................................................... 4
Media Sensor, Cleaning ............................... 33
Operating ..................................................... 16
Power Switch ................................................. 4
Power Switch, Main ........................................ 4
Set-Up .......................................................... 15
Sheet Separator, Adjust ............................... 16
Speed Control ................................................ 4
Stop Button .................................................... 4
Vacuum Plate, Install ................................... 15
Vacuum Pump Filter, Cleaning..................... 34
Vacuum Switch .............................................. 4
Assembly
Image System II ............................................. 8
Auto/Manual Switch
Dryer .............................................................. 2
B
FF-14 Feeder ................................................. 3
Transport ........................................................ 2
Base Media Guides, Adjust ............................. 17
Batch Counter, FF-14 Feeder ............................ 3
Blower Switch, Dryer ......................................... 2
C
Cleaning
ASF-3000 Feeder ......................................... 33
Feed Rollers, ASF-3000 Feeder .................. 33
FF-14 Feeder ............................................... 32
Image System II ........................................... 31
Jar Filter, ASF-3000 Feeder ......................... 33
Media Sensor, ASF-3000 Feeder ................. 33
Media Sensor, Image System II ................... 32
Printhead, Printer ......................................... 29
Vacuum Pump, ASF-3000 Feeder ............... 34
Computer Monitor Support ................................ 1
Computer Requirements .................................. 44
Continuous Feed Switch, FF-14 Feeder ............ 3
Control Panel ................................................... 2
Auto/Manual Switch, Dryer ............................. 2
Auto/Manual Switch, Transport ...................... 2
Blower Switch, Dryer ...................................... 2
Conveyor Controls ......................................... 2
Dryer Section Controls ................................... 2
Main Control .................................................. 2
Power Switch, Conveyor ................................ 2
Power Switch, Dryer ...................................... 2
Power Switch, Main ....................................... 2
Power Switch, Transport ................................ 2
Printer ...................................................... 5, 23
Speed Control, Conveyor ............................... 2
Speed Control, Dryer ..................................... 2
Speed Control, Transport ............................... 2
Stop Button, Main .......................................... 2
Transporter Section Controls ......................... 2
Vacuum Switch, Transport ............................. 2
Conveyor Stacker .............................................. 1
Counter
ASF-3000 Feeder .......................................... 4
D
Databases ....................................................... 26
Disposal, Inkjet Cartridges ............................... 29
Dryer
Install ............................................................. 9
Dryer Base ....................................................... 1
E
Attach ............................................................. 9
ENTER Key, Printer..................................... 5, 25
F
FAULT Indicator, Printer .................................... 5
FF-14 Friction Feeder ...................................... 1
Auto/Manual Switch ....................................... 3
Batch Counter ................................................ 3
Cleaning ....................................................... 32
Continuous Feed Switch ................................ 3
Control Panel ................................................. 3
Sensors, Cleaning........................................ 32
Set-Up .......................................................... 14
Sheet Separators ......................................... 31
Single Feed Switch ........................................ 3
Speed Control ................................................ 3
Filter, Vacuum Pump ....................................... 34
I
Image System II ............................................... 1
Assembly ....................................................... 8
Base Media Guides, Adjust .......................... 17
Cleaning ....................................................... 31
Computer Monitor Support ............................. 1
Control Panel ................................................. 2
Conveyor Stacker .......................................... 1
Dryer Base ..................................................... 1
Install ............................................................. 7
Main Base Unit............................................... 1
Maintenance ................................................ 28
INDEX
Media ........................................................... 26
Media Sensor, Cleaning ............................... 32
Operating ..................................................... 21
Printer ............................................................. 1
Troubleshooting ........................................... 35
Wiring and Connecting ................................. 10
Inkjet Cartridges
Disposal ....................................................... 29
Install ............................................................ 13
Maintenance ................................................. 28
Remove/Replace .......................................... 28
Storage ......................................................... 29
Install
Dryer .............................................................. 9
Image System II ............................................. 7
Inkjet Cartridges ........................................... 13
Printer Software ........................................... 19
Vacuum Plate, ASF-3000 Feeder ................ 15
J
Jams, Printer .................................................... 30
Jog Button, ASF-3000 Feeder ........................... 4
M
Main Base Unit .................................................. 1
Main Power Switch
ASF-3000 Feeder ........................................... 4
Image System II ............................................. 2
Main Stop Button ............................................... 2
Maintenance ................................................... 28
ASF-3000 Feeder ......................................... 33
FF-14 Feeder ............................................... 32
Image System II ........................................... 31
Inkjet Cartridges ........................................... 28
Printhead ...................................................... 29
Media Thickness .............................................. 26
Media Thickness Knob, Printer .......................... 5
Media Types .................................................... 26
MENU Key, Printer ...................................... 5, 23
O
ON LINE Key, Printer ................................... 5, 25
Operator Display, Printer ................................... 5
P
Power Switch
ASF-3000 Feeder ........................................... 4
Conveyor ........................................................ 2
Dryer .............................................................. 2
Main ............................................................... 2
Transport ........................................................ 2
Printer ............................................................... 1
- Key ......................................................... 5, 25
+ Key ........................................................ 5, 25
Control Panel ........................................... 5, 23
ENTER Key .............................................. 5, 25
FAULT Indicator ............................................. 5
Jams ............................................................. 30
Media Thickness Knob ................................... 5
MENU Key ............................................... 5, 23
ON LINE Key ........................................... 5, 25
Operator Display ............................................ 5
Printhead, Cleaning ..................................... 29
Purge ........................................................... 25
RESET Key .............................................. 5, 25
Software, Install ........................................... 19
TEST Key .................................................... 23
TEST PRINT Key ........................................... 5
Purge, Printer .................................................. 25
R
Remove/Replace
Inkjet Cartridges ........................................... 28
RESET Key, Printer ..................................... 5, 25
S
Set-Up
ASF-3000 Feeder ........................................ 15
FF-14 Feeder ............................................... 14
Sheet Separator
ASF-3000 Feeder ........................................ 16
Single Feed Switch, FF-14 Feeder .................... 3
Specifications .................................................. 43
Speed Control
ASF-3000 Feeder .......................................... 4
Conveyor ....................................................... 2
Dryer .............................................................. 2
FF-14 ............................................................. 3
Transport ....................................................... 2
Stop Button
ASF-3000 Feeder .......................................... 4
Main ............................................................... 2
Storage, Inkjet Cartridges ................................ 29
Supplies ........................................................... 44
T
TEST Key, Printer............................................ 23
TEST PRINT Key, Printer .................................. 5
Troubleshooting ............................................ 35
Feeding Problems ........................................ 36
Interface Communication ............................. 35
LCD Display ................................................. 36
Power Problems........................................... 35
Print Content, Incorrect ................................ 39
Print Placement............................................ 38
Print Quality ................................................. 40
V
Software Problems....................................... 39
Vacuum Pump Cleaning .................................. 34
Vacuum Switch
ASF-3000 Feeder .......................................... 4
Transport ....................................................... 2
Copyright
©
2015 All rights reserved
03/24/2015
Part Number : 500-IMAGE SYSTEM II Rev. B
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Key Features
- Automatic and manual mode
- Vacuum shuttle feeder
- Handles a variety of media types
- High-quality inkjet printer
- Simple control panel
- Large LCD display
- Handles pieces up to 1/2-inch thick
Frequently Answers and Questions
How do I set up the Image System II to print in automatic mode?
How do I purge the printheads?
How do I replace the ink cartridges?
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