Rena AS-150 Service Manual
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Rena AS-150 Service Manual

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AS-150 PRINTER

SERVICE MANUAL

Rev 10-14-15

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Summary of Contents for Rena AS-150

  • Page 1: Service Manual

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

  • Page 2: Safety Precautions

    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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents SECTION 1 – Installation Contents of Packaging Assembling Printer Install Rear Media Support Install Rear Media Guide Connecting Printer Install Inkjet Cartridges Set up Feed Install Printer Driver BIOS Manager SECTION 2 – Troubleshooting Service Diagnostic Tests Sensor Test SECTION 3 –...

  • Page 4: Section 1 - Installation

    SECTION 2 INSTALLING PRINTER SECTION 1 – Installation Contents of Packaging AS-150 Printer Power Cord Software Side Guides Rear Media Support & Guide Operator Manual Assembling Printer Tools required: Standard #2 Phillips head screwdriver. Install Side Guides Remove two screws from Side Guide Blocks.

  • Page 5: Install Rear Media Support

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

  • Page 6: Connecting Printer

    SECTION 2 INSTALLING PRINTER Connecting Printer Plugging in Printer Make sure Printer’s Main Power Switch is turned OFF. Connect one end of power cord to rear receptacle on Printer. 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...

  • Page 7: Install Inkjet Cartridges

    SECTION 2 INSTALLING PRINTER Install Inkjet Cartridges Printer has 3 Inkjet Cartridges. To install Cartridges: Remove Inkjet Cartridge from packaging. Take care not to touch copper contacts, metal plate, or gold printhead. Remove protective tape from Printhead. Open Latch Lever mounted on Inkjet Cartridge Holder.

  • Page 8: Set Up Feed

    SECTION 2 INSTALLING PRINTER Set up Feed Printer has two Sheet Separators, two Side Guides, and a Rear Media Support and Guide. Adjust Sheet Separators individually as follows: Move Side Guides to access locking screws. Loosen locking screw(s) [A] (as shown) and raise Separator.

  • Page 9: Install Printer Driver

    SECTION 2 INSTALLING PRINTER 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. Close any applications running on your computer. Restart computer before installing Driver. Install CD in CD drive: Click “Open folder to view files”.

  • Page 10: Bios Manager

    SECTION 2 INSTALLING PRINTER 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.

  • Page 11: Section 2 - Troubleshooting

    SECTION 2 TROUBLESHOOTING 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, No power to Printer Check that power cord is plugged in.

  • Page 12: Feeding Problems

    SECTION 2 TROUBLESHOOTING LCD Display Problems CONDITION PROBLEM SOLUTION No LCD display Power not ON Turn power switch ON. If still no display, see Power Problems. Contrast Pot broken or maladjusted Adjust Pot or replace Display PC Board. (see Section 4-Adjustments) Broken solder joint on Contrast Pot Repair or replace Display PC Board.
  • Page 13 SECTION 2 TROUBLESHOOTING Feeding Problems (continued) CONDITION PROBLEM SOLUTION Side Guides too close to media Readjust Side Guides. Failure to feed ENTER key not pressed Instruct user on proper operation. No power to Printer Check power button is ON and power cord is plugged in.

  • Page 14: Printing Problems

    SECTION 2 TROUBLESHOOTING Printing Problems CONDITION PROBLEM SOLUTION No printing: Media is blank Sensor did not see the piece or Clean or replace Sensor. after going under Printheads send signal to print to PC Board Clogged Cartridges Clean and purge Cartridges. Cartridge dried out Install new Cartridge.
  • Page 15 SECTION 2 TROUBLESHOOTING Printing Problems (continued) CONDITION PROBLEM SOLUTION Adjust to 14 VDC. (See “Output Non-uniform print quality Check voltage from power supply Voltage Adjustment”) Poor Printhead connections Check that Flex Circuit connections are in place. White lines/streaks in a Ink Cartridge Nozzle dirty Clean Cartridge.
  • Page 16 SECTION 2 TROUBLESHOOTING Print Placement Problems CONDITION PROBLEM SOLUTION Size of media not set correctly Check layout in Layout for Print too close to leading or trailing edge of media in Layout proper size. Bad or dirty Sensor Clean or replace Sensor. Feed Ramp not used properly Set Feed Ramp.

  • Page 17: Print Content Incorrect

    SECTION 2 TROUBLESHOOTING Print Content Incorrect CONDITION PROBLEM SOLUTION Information being printed Poor cable connections Check USB cable: is wrong, incomplete, Securely fastened at both ends. or garbled Cable length not more than 6-ft. Printer's internal USB cable in good condition. Interface problem Check Printer setup at computer.

  • Page 18: Service Diagnostic Tests

    SECTION 2 TROUBLESHOOTING 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 –...

  • Page 19: Section 3 - Functional Operation

    SECTION 3 FUNCTIONAL OPERATION SECTION 3 – Functional Operation Sequence of Operation User Prepares the Printer Selects number and color of Print Cartridges required and installs Cartridges in proper location. Uses a single piece of media to set Sheet Separators. Loads media and adjusts Side Guides to within 1/32"...

  • Page 20: Printer Control Panel

    SECTION 3 FUNCTIONAL OPERATION 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 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.

  • Page 21: Printer Control Panel

    SECTION 3 FUNCTIONAL OPERATION Printer Control Panel When Printer is first turned ON, TEST PRINT key lights and display becomes active. At this point, Printer is ready to print if it is connected to computer. Printer Control Panel Keys are used to access various functions that help control Printer.

  • Page 22: Reset Key

    SECTION 3 FUNCTIONAL OPERATION Automatic Feed – Turning feature ON causes Printer to start feeding once job is sent. If ON LINE key is ON, Printer starts feeding and printing automatically. To press ENTER to start printing process, turn this feature OFF. Turning Printer ON or OFF does not affect your selection. Pause Type: –...

  • Page 23: Purge While Printing

    SECTION 3 FUNCTIONAL OPERATION Purge While Printing To Purge in the middle of a job: Press ONLINE key to pause current job. Press MENU, then step to “Press Enter to Purge”. Press ENTER to start purge and press ENTER again to stop purge. Press ONLINE, then ENTER to get back to normal printing.

  • Page 24: Printer Driver Properties

    SECTION 3 FUNCTIONAL OPERATION Printer Driver Properties Printer Driver describes to Printer how to print your job. It controls Printer operation and allows you to send fixed and variable text and graphics to Printer. Within your data management software is a “Print” function.

  • Page 25: Document Options

    Resolutions: Sets resolution of print quality. Changing resolution to a higher number (e.g. 200 DPI to 600 DPI) increases image quality. AS-150 Resolution Speeds Available 600 x 150 DPI 600 x 200 DPI...
  • Page 26 SECTION 3 FUNCTIONAL OPERATION Head Adjustment Permits slight (0.001") adjustments to Printhead's positions in relation to each other. Adjustment is used to precisely align Printheads when printing graphics or type that extends beyond width of one Printhead. Each Head can be moved +/- 0.048" in 0.001" increments. To move Printhead toward the lead edge of the layout, move it in “-”...

  • Page 27: Pc Board And Electrical Component Location

    SECTION 3 FUNCTIONAL OPERATION PC Board and Electrical Component Location Non-Operator Side Operator Side Left-hand Cover View...

  • Page 28: Section 4 - Adjustments

    SECTION 4 ADJUSTMENTS SECTION 4 – Adjustments WARNING! ELECTRICAL ADJUSTMENTS ARE MADE WITH PRINTER UNDER POWER. USE NONMETALLIC TOOLS WHEN ADJUSTING POTENTIOMETERS ON PC BOARDS. Drive Belt Tension Adjustment REQUIREMENT: To ensure Drive Belt is properly tensioned. ADJUSTMENT: Unplug Printer and remove Non- Operator Side Cover.

  • Page 29: Encoder Belt Tension Adjustment

    SECTION 4 ADJUSTMENTS Encoder Belt Tension Adjustment REQUIREMENT: To ensure Encoder Belt is properly tensioned. ADJUSTMENT: Unplug Printer and remove Operator Side Cover. (5 screws) Loosen three screws [2] that mount Encoder to Side Frame. Move Encoder [1] up or down in slots until you obtain at least a 1/8"...

  • Page 30: Output Voltage Adjustment

    SECTION 4 ADJUSTMENTS Output Voltage Adjustment REQUIREMENT: To provide proper output from Power Supply to Printer. ADJUSTMENT: Remove Non-Operator Cover and connect Adjust Potentiometer [3] on Power Supply voltmeter probes to GND [1] and +15V [2] on Module to obtain 14 VDC ± 0.1 V. Interface PC Board.

  • Page 31: Media Sensor Adjustment

    SECTION 4 ADJUSTMENTS Media Sensor Adjustment REQUIREMENT: To assure that Media Sensor senses media. ADJUSTMENT: Remove Non-Operator Cover and connect Adjust R2 Potentiometer [3] to read voltmeter probes to GND [1] and TP2 [2] on 0.5 VDC maximum. Interface PC Board. Turn Printer OFF.

  • Page 32: Lcd Display Adjustment

    SECTION 4 ADJUSTMENTS LCD Display Adjustment REQUIREMENT: To increase/decrease LCD Display intensity/brightness. ADJUSTMENT: Remove Operator Cover. Leave ribbon cable Adjust Display's brightness level as desired. connected. Turn Printer turned ON. Turn Printer OFF. Apply lacquer (such as Find the LCD Brightness Control nail polish) to Potentiometer to prevent potentiometer [A].

  • Page 33: Brake Adjustment

    SECTION 4 ADJUSTMENTS Brake Adjustment REQUIREMENT: To provide proper tension on Feed Shaft Brake Assembly for proper feeding of media. ADJUSTMENT: Disconnect Printer from power source. Load media and turn Printer ON. Press TEST PRINT key, then ENTER to start feeding Remove Operator Side Cover, media.

  • Page 34: Section 5 - Disassembly/Assembly Procedures

    SECTION 5 DISASSEMBLY – ASSEMBLY SECTION 5 – Disassembly/Assembly Procedures Tools Required #2 Phillips head screwdriver 3/32" Allen wrench #1 Phillips head screwdriver 5/32" Allen wrench Basic Disassembly Turn off power. Disconnect Power Cord. Disconnect Interface Cable.
  • Page 35 SECTION 5 DISASSEMBLY – ASSEMBLY Removing Side Guides Remove four screws (two each side). Removing Rear Media Support Remove two screws [A] (as shown). Lift assembly from machine. Removing Print Cartridges Lift Blue Lever. Remove Cartridge. Close Lever.

  • Page 36: Replacing Separator Tips

    SECTION 5 DISASSEMBLY – ASSEMBLY Replacing Separator Tips Before replacing Separator Tips, unplug Printer. Loosen Separator Locking Knob [A]. Use a Phillips screwdriver and remove screw holding metal cover over Separator [B]. Use screwdriver tip to pry Separator Tip out of its holder.

  • Page 37: Service Disassembly Procedures

    SECTION 5 DISASSEMBLY – ASSEMBLY Service Disassembly Procedures NOTE: The following disassembly should only be done by a qualified, trained service representative. CAUTION ALWAYS WEAR A GROUNDED WRIST STRAP WHEN WORKING WITH ELECTRONIC BOARDS. OPERATOR SIDE COVERS Remove two screws from top of Operator Side Cover and one on side.
  • Page 38 SECTION 5 DISASSEMBLY – ASSEMBLY Major Components under Operator Side Cover: Drive Motor Encoder Drive Belt Encoder Main Power Supply NON-OPERATOR SIDE COVER Remove two screws from top of Non-operator Side Cover. Then remove two screws from bottom of Cover. Remove Cover.
  • Page 39 SECTION 5 DISASSEMBLY – ASSEMBLY USB/INTERFACE PC BOARD 1. USB PORT CONNECTION 2. CLUTCH 3. MOTOR 4. CONTROLLER 5. MEDIA SENSOR 6. 15VDC IN – Power input for Interface PCB 7. USB INTERFACE with Main PC Board MAIN PROCESSOR PC BOARD USB PORT ENCODER PRINTER DRIVER...
  • Page 40 SECTION 5 DISASSEMBLY – ASSEMBLY REMOVING REAR COVER Remove Rear Media Support, and Operator and Non-Operator Side Covers. Remove screws attaching Rear Cover [A] to Side Frames. (3 per side). Remove Cover. REPLACING PRINTHEAD ASSEMBLY Remove two Printhead Assembly mounting screws [A] (1 on each side).
  • Page 41 SECTION 5 DISASSEMBLY – ASSEMBLY Remove screw [C] to remove Media Sensor Assembly [D] from Printhead Assembly. Lift Printhead Assembly from Carriage Holder. Reassemble in reverse order. REMOVING EXIT COVER Remove Print Head Assembly, Operator and Non-Operator Side Covers, and Main Processor PC Board.
  • Page 42 SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING SHEET SEPARATOR ASSEMBLY Remove Media Side Guides (2 screws on each side.) Remove Operator and Non-Operator Side Covers. (May also be necessary to remove Main PC Board to access mounting screws on Non-Operator side.) Remove 3 mounting screws on Non-Operator side [A].
  • Page 43 SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING CLUTCH Remove Non-Operator Side Cover. Remove Clutch Bracket [1]. Then loosen Motor mounting screws [2]. Disconnect Clutch wiring harness [3] from Interface PC Board (J4). Lift Motor to loosen Motor Drive Belt [4]. Push Clutch in toward Frame and remove locking pin [5].
  • Page 44 SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING DRIVE MOTOR, DRIVE BELT, MAIN PC BOARD, AND POWER SUPPLY Remove Operator Side Cover, Non-Operator Cover, Main PC Board. Remove Main PC Board*: Remove 4 mounting screws, then carefully remove PC Board. (Carefully disconnect wiring if removing Board completely.) *Not necessary to remove...
  • Page 45 SECTION 5 DISASSEMBLY – ASSEMBLY Remove Power Supply*: [A] Disconnect wire harnesses and ground wire from Power Supply. [B] Remove four screws that attach Power Supply to Printer Base. [C] Remove Power Supply. *Not necessary to remove Main PC Board to remove Power Supply.
  • Page 46 SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING MAIN FEED ROLLER Remove Non-Operator and Operator Side Covers. Remove Main Feed Roller. Non-Operator Side: Remove Clutch Bracket [1]. Loosen Motor mounting screws [2]. Disconnect Clutch wiring harness [3] from Interface PC Board (J4). Loosen Motor mounting screws.
  • Page 47 SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING REAR FEED, TRANSPORT AND EXIT ROLLERS Rear Feed Roller [2], Transport Roller [3] and Exit Roller [4] may be removed as follows. (Instructions for removing Main Feed Roller [1] are listed above.) Remove Operator and Non- Operator Side Covers, and Rear Cover.
  • Page 48 SECTION 5 DISASSEMBLY – ASSEMBLY REPLACING TRANSPORT BELT Remove Print Head Assembly, Operator and Non-Operator Side Covers, and Main Processor PC Board. Transport Roller: Non-Operator side – Loosen Motor mounting screws to loosen Motor Drive Belt. Remove Belt from Transport Roller Drive Pulley [D].

  • Page 49: Section 6 - Maintenance

    SECTION 6 MAINTENANCE SECTION 6 – Maintenance This section covers how to care for Ink Cartridges, clear paper jams, replace Sheet Separators, and perform routine maintenance on Printer. Inkjet Cartridge Inkjet Cartridges must be replaced when out of ink, when print quality is poor, or when purging and cleaning have not helped image quality.
  • Page 50 SECTION 6 MAINTENANCE Storage Short-term Storage: (less than 2 days or less than 1 day in a hot and dry environment.) Leave Cartridge in Printer for short periods of time, 1 day or less. Next time that Printer is used, Printhead may have to be cleaned and purged. Long-term Storage: (more than 2 days or more than 1 day in a hot and dry environment.) Keep Printhead in an area that is relatively free of dust and paper particles that is not too dry.

  • Page 51: Jams In Printer

    SECTION 6 MAINTENANCE Purging Nozzles If Printhead sits inactive for a period of time, ink may dry in the Nozzles. Printing may not remove these “ink plugs” from the Nozzles. White streaks appear in printed text or graphic. In improve print quality, these ink plugs need to be forced out or purged.

  • Page 52: Cleaning

    SECTION 6 MAINTENANCE Cleaning WARNING! PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT PRINTER FROM ITS POWER SOURCE! Printer must be cleaned regularly of accumulated paper dust and ink. Depending on types of media run, paper dust may accumulate within Printer and on Transport.

  • Page 53: Appendix A - Printer Specifications

    APPENDIX A APPENDIX A – Printer Specifications PRINT TECHNOLOGY Inkjet, Three HP 45 High Capacity Inkjet Cartridges 110 ft./minute – 22 in./second (33.5 m/minute – 55.6 cm/second) BELT SPEED High Quality 600 x 600 DPI PRINT QUALITY Standard Quality 600 x 300 DPI (Dots Per Inch) Letter Quality 600 x 200 DPI...

  • Page 54: Appendix B - Supplies

    APPENDIX B APPENDIX B – Supplies The following supply items are available from your Distributor: Supplies Red Inkjet Cartridge Green Inkjet Cartridge Blue Inkjet Cartridge Yellow Inkjet Cartridge Versatile Black General Black (works on high gloss media when used with dryer)

  • Page 55: Index

    INDEX Adjustments ............ 26 Electrical Components Location .......25 Brake ............31 Encoder Drive Belt Tension ........26 Belt ...............41 Encoder Belt Tension ........27 Belt Adjustment ..........27 LCD Display ..........30 Replace ............41 Media Sensor ..........29 ENTER Key ............18 Output Voltage ..........
  • Page 56 INDEX Purge While Printing ........21 Sequence of Operation ........17 Maintenance ............ 47 Side Guides, Remove ........33 Cleaning............50 Specifications..........51 Injet Cartridge ..........47 Supplies ............52 Printer Jams ..........49 Troubleshooting ..........9 Printheads ............. 48 Printer Driver Sheet Separators ........... 49 Install .............
  • Page 57 INDEX Sheet Separator Assembly, Replace ........40 Replace ............49 Tips, Replace ..........34 Side Guides Install .............. 2 Remove ............33 Software Problems, Troubleshooting ....15 Specifications, Printer........51 Storage, Inkjet Cartridges ......... 48 Supplies, Printer ..........52 TEST PRINT Key ..........18 Transport Roller, Replace .........
  • Page 59 © Copyright 2015 Neopost USA.

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