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Maximailer Plus - Neopost Technologies Ltd

1. Unit Fine tuning Module 0 Head Conf ig Fine Tuning single A4 Hardware Fine Tuning Module 0 Head comepasaomm l o A O SS C A e S e S S e e S e e S mmmn o cun Fine Tuning X Abort af Do It toggle between fine tuning for unit and hoppet Unit Fine Tuning Click on the envelope inserter on the machine graphic to display the fine tuning screen Click on Hardware Fine Tuning to display further information You can select a The width of the collate pocket guides b The overall width of the insert fingers c The time allowed for the flap to seal before the envelope is ejected d Adjustment of the point at which the wetter beam drops to wet the flap ve increases wetting in 1mm steps moves start point towards insertion area e Adjustment of the point at which the wetter beam lifts ve increases duration ie a greater length of flap is wetted befor the beam is lifted f Adjustment of the amount of envelope travel into the sealing rollers ve further forward away from exit direction g Adjustment of the envelope stop position for insertion ve further forwards towards exit direction h Adjustment of the amount of insertion of the insert pack into the enve lope ve further forwards past the flap crease i Adjustment of the amount of envelope foward travel after flap wetting before reversing to enter the sealing roller
2. Datacard ig Blank Page Page 5O MAXIMAILER PLUS OPERATING INSTRUCTIONS
3. Documents Envelopes Configuration Job Users Statistics Engineering Admin Run Screen MAXIMAILER PLUS OPERATING INSTRUCTIONS Description of Button Functions n E v ce ce cs Touch the OMR Code button to view all current OMR settings Touch the Bar Code button to view all current barcode settings Touch the Documents button fo view all current Document settings Touch the Envelopes button to view all current envelope settings Touch the Configuration button to view all current configuration settings Touch the Job button to wiew all current jod settings Touch the User button to view all current user settings Touch the Statistics button to view Job statistics Touch the Engineering button to view all current engineering settings Touch the Admm button to view all current admin settings Allows OMR mark settings to be created viewed or altered Allows Bar Code settings to be created viewed or altered Allows form and insert settings to be defined or altered Allows envelope settings to be defined or altered Configure the machine for all settings to use with the selected stationery Create a new job or alter an existing one Allows a new user to be added and a password and permissions to be set These can be also be altered for existing operators Displays information on current machine settings production run data etc Allows testing of various parts of the machine Only available to
4. click the Postage button and enter the rate for that group Press Enter Repeat the above steps for the remaining groups if required Note The weight of the filled envelope is determined by the weight of each inserted document and the envelope These are set in the Document and Envelope options in the Setup screen see pages 23 amp 25 MAXIMAILER PLus OPERATING NSTRUCTIONS Datacard Setting the output options This op tion is only available if a conveyor is fitted Select Save as Default to make this the default for all new setups Envelope batching Maximailer Plus User Manual 5 5 The Configuration Screen contd Ensure that the Output tab in the configuration screen is selected This section allows you to set up batching on the output conveyor where fitted Note This screen will only be available to personnel with Supervisor access Configuration Untitled Config1 SGontrolisertines Quantity mode Envelopes count Quantity 200 Control Mode Auto restart Jog step Pausetime If batching is used the machine will either stop or wait for a predetermined time period to allow removal of envelopes before restarting To use batching press the Output Conveyor button and select Batch on Press the Control button to display the settings dialog as shown above The only Quantity mode available is Envelopes count Set the required
5. s own data file to divert using the ID field label instead of the Divert BCS Character Set to On to divert for this job only or set to ALP to divert on occurrence of label in any job Note that the Divert BCS character can also be used in conjunction with ID field label Not currently used MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 35 Datacard H Maximailer Plus User Manual 5 7 The Users Screen User Russell Operator l Senior Operator L Supervisor M Engineer l Admin L Special v Superuser _ RunScreenShow RunScreenStandard l RunScreenAll _ TwiddleDocShow _ TwiddleDocStandard l TwiddleDocAll L SetupShow _ SetupStandard Note This screen will only be available to personnel with Supervisor access From this screen you can edit the user that was selected in the list box see page 18 or click on New if creating a new user The user name password and access levels can be changed Editing the password Editing the user name Setting the roles Page 36 Click on Password and edit the password as required either by typing it or by using the on screen keyboard This is the password that must be entered when the user is selected from the Run screen Note the password is case sensitive Click on User name and edit the name as required either by typing it or by using the on screen keyboard Any changes made here will be reflected in the User list
6. Started 0 No Fault 0 0 9 E 5727 2004 11 41 23 Am4 Test Job Internal Configuration Change 0 No Fault 0 0 9 E 5727 2004 11 37 22 Am4 Test Job Internal Configuration Change 0 No Fault 0 0 9 Touch tH E 5 27 2004 11 34 48 m4 Test Job Internal Stopped by Operator 0 No Fault 0 0 9 E 5 27 2004 11 34 45 Am4 TestJob Internal Machine Started 0 No Fault 0 0 9 E 5727 2004 11 25 44 Am4 Test Job Internal Configuration Change a No Fault 0 0 9 Touch y 528 2004 180801 Amd Test Job Internal Configuration Change O No Fault 0 0 3 E 5 26 2004 18 04 38 Am4 Test Job Internal Configuration Change 0 No Fault 0 0 9 E 5726 2004 17 31 43 Am4 Test Job Internal Configuration Change 0 No Fault 0 0 9 E 5726 2004 17 31 41 st3 test 3 Internal Configuration Change 0 No Fault 0 a g Touch th E 5 26 2004 14 40 54 t3 test 3 Internal Configuration Change 0 No Fault 0 0 9 E 5 26 2004 14 36 53 st3 test 3 Internal Configuration Change 0 No Fault 0 0 9 5 26 2004 14 18 25 st3 test 3 Internal Configuration Change a No Fault 0 0 9 MG rmscrcon E 5726 2004 13 14 38 st3 test 3 Internal Configuration Change 0 No Fault 0 0 g E 5 26 2004 11 18 45 st3 test 3 Internal Configuration Change 0 No Fault 0 0 9 E 5 25 2004 13 05 15 st3 test 3 Internal Configuration Change a No Fault 0 0 9 E 5 25 2004 13 03 45 st3 test 3 Internal Configuration Change 0 No Fault 0 0 9 E 5 25 2004 13 03 22 st3 test 3 Internal Configuration Change 0 No Fault 0 0 9 E 5 25 2004 11 16 39 st3 test 3 Internal Configuration Chang
7. or use the on screen keyboard and press return note that the password is case sensitive Assuming the correct password has been entered the Run Screen will be available for use as shown on the following page User button 15 13 1 21 2005 Russell Single A4 etette 283 geste Note New operators and passwords can be only be entered or edited by authorised personnel with Supervisor access This is detailed in section 5 5 The Configuration Screen on page 27 Page 4 0 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximatier Plus User Manual Datacard 4 The Run Screen The Run screen From this screen you run and stop the machine and control the speed It is explained also possible to change the selected user change the selected job and enter Edit Configuration authorised personnel only Current time Select user Machine Select Exit to setup Exit and date graphic job screen software Y 12 72006 12 35 28 Russell Single A4 275 e gt d A a w wh S AF Status Powering up please wait 41 lt Reset Autoend Flush Run count button Output rate Speed control Double Process Stop indicator and indicator document one cycle button calibrate To change the current user or job click on the buttons and you will be presented with a list of all those that have been created and allow you to select any one Note that to change to a different user will require the
8. personnel with engineer access and described in detail in the Automailer 5 Service Manual Allows administration of various machine functions Click on this to take you back to the Run Screen Page 1 Maximailer Plus User Manual Datacard i 5 The Setup Screen contd The List Box San Click on any of the buttons on Currently selected the Setup screen to display a list A4 275 box Shown left is the list box ForminsertiD 275 Document name A4 kd s orm type Form e m for the Document and is similar Width mm 210 Letter 108 eo for all of the buttons on the Thickness mm 0 11 E Cheque 262 Setup screen The list box salsa ee shows all of the setups that have been defined so far Select any of the setups shown and Ba E this can then be edited copied or deleted by clicking on the 7E9900 p appropriate button at the bot tom of the box New setups can also be created by clicking on the New button and the newly created item can then be edited as required Note that each name is allocated an ID number by the software this being as Gen appended to the name You can sort the list by ID or name and if the list is long and a scroll bar appears you can also search the list by name or ID using the buttons at the bottom A filter can also be applied to list only names or IDs containing criteria such as a keyword or a part of it c5 am5 card 281 When either
9. the Name button and editing as required either by typing or by using the on screen keyboard Warning Do not change the name of an existing configuration that is associated with a current job If you do the factory configuration Default Config will be substituted Configuring the Click the upper icon on the Head part of the graphic showing the enve inserter lope icon This displays the list of available envelopes to allow you to select one see page 25 for creating Envelopes If the machine has more than 6 stations use the scroll arrows to move sideways Envelopes Please select item from list Select the required envelope and click Ok Note An error will occur if an envelope that is used in any configuration has been deleted from the list box in the Setup screen see page 18 MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 27 Datacard Maximailer Plus User Manual 5 5 The Configuration Screen contd Setting the Click on the bottom section of the Inserter showing the unit icon and the inserter options following dialog box appears for the Inserter unit Moduls U rlouper Head standard hopper Envelope Default Seal Mode Deskew Select Save as Default to make this the default for all new setups These settings then apply to Load Default ee Seal Mode Options are Off Always Unseal OMR Select Off Flap Open if Off is selected flap
10. you select items that need setting up The OMR Code Screen to allow you to define OMR marks for up to four reader heads The Bar Code Screen to allow you to define Barcode characters The Documents Screen for defining the forms or inserts to be used The Envelopes Screen for defining the envelope to be used The Configuration Screen where you set up the envelope inserter and feeder units to use the selected stationery The Job Screen to allow you to define a job name and associate it with a machine configuration The User Screen for creating operator names and allocating a password and access permissions The Statistics Screen for viewing production data Setting up the machine for loading stationery etc To provide assistance through the various operating screens there will always be a symbol available Click on this to display a popup box detailing further information for the area of the software you are using MAXIMAILER PLUS OPERATING INSTRUCTIONS Page Q Maximailer Plus User Manual Datacard i 4 The Run Screen Starting the When you first start the operating program you will be presented with the Operating Run Screen shown below and described in detail on the following page Program The program will start with the last used operator and configuration as shown at the top of the screen To log on as another user press the User button and select one from the list Enter the password either by typing it in
11. 8 Width 19mm 3 4 Total Pack thickness for insertion 6mm 1 4 max NOTE Insert Requirements for Optimum Running Inserts should be sufficiently flexible to suit the transport path restraints The maximum allowable width difference between inserts is 32mm 11 If this difference in width is exceeded the insertion fingers will not cover the side edges of the narrow insert and cause an insertion problem Sandwiching a narrow insert between two wider ones may resolve this Inserts should be dimensionally symmetrical for optimum running Asymmetric inserts eg thicker on one side than the other will not seat well in the feed hopper and this can affect feed and separation Part loading of the hopper can overcome this but it will require more frequent loading Inserts should be flat and free from distortion Care must be taken in the storage of inserts inadequate stacking by a supplier can result in curved edges and spines causing inserts to seat poorly in the feed hopper Feeding of booklets can be particularly adversely affected by distortion Booklets require a spine to edge thickness ratio of less than 1 25 1 for optimum running This can have a major effect on how well booklets load into a feed hopper and consequently the feeding efficiency A minimum overlap or clearance of 5mm 3 16 is required between an insert edge and the innermost edge of the carrier envelope side seam If the edge of an insert runs close to t
12. Address carrier Feed Control Mode Feed always Fold mode Mark Reading Thickness doubles Deskew m Select Save as Default to make this the default for all Seen new setups These settings then apply to Load Default A 0 00 0 75mm fase nonren Baione on xX emen Address Carrier Select whether or not this is the address document Note this can also be selected from Miscellaneous see page 35 Which ever is set the later takes precedence Feed Control Mode Options are Off Feed Always OMR or Barcode Select the latter only available if unit is OMR Barcode enabled Fold Mode 3 plate folder only Options are Singly Together Via accumulator the latter is only available if the unit has an accumula tor fitted if so forms will group in accumulator first before folding only Form Count Only available if Mark reading is Off If multiple forms are required set this to the required quantity Note ensure that the maximum fold capacity is not exceeded Mark Reading Only available if unit is OMR Barcode and a marked document is selected Options are Off OMR marks Barcode labels 2D Datamatrix OCR Thickness Doubles Set to Off if for example the documents being run are substantially different from the calibration document such as abnormally dark with heavy printing Deskew Set the amount of envelope deskew required Note a higher level will slow the
13. Datacard Maximailer Plus User Manual 1 Technical Specification SECTION 1 TECHNICAL SPECIFICATION Form Sizes Insert Feeder Unit Insert Sizes Single Hopper Depth Width Thickness 76mm 3 min for module 1 89mm 3 min for following modules 152mm 6 max 165mm 6 min 241mm 9 max 60 gsm 16lbs bond min 4mm 5 32 booklets max See also notes on following page Hopper capacity Up to 300 reply paid envelopes or 150 2mm booklets Insert Sizes Dual Hopper amp OMR Feeder Depth Width Thickness 76mm 3 min for module 1 either or both hoppers amp OMR 89mm 3 min for folowing modules 152mm 6 max 165mm 6 min 241mm 9 max 60 gsm 16lbs bond min 4mm 5 32 booklets max lower hopper 2mm 5 64 booklets max upper hopper See also notes on following page Hopper capacity Up to 200 reply paid envelopes or 100 2mm booklets Datacard Turnover Interface Unit Document Sizes Width Folded length Thickness MAXIMAILER PLUS OPERATING INSTRUCTIONS 222mm 8 75 max min as for insert feeder 150mm 5 7 8 3mm 1 8 max Page 3 Maximatiler Plus User Manual Datacard H 1 Technical Specification cont Minimum clearance of insert pack inside envelope Up to 3mm thick pack Depth 6mm 1 4 Width 14mm 9 16 3 6mm thick pack Depth 10mm 3
14. Datacard amp Contents 2 1 2 2 5 1 3 2 93 5 4 3 9 5 6 o 5 8 8 Safety Notes Technical Specification Machine Layout Guide Description of Machine Parts Identification About this Document The Run Screen To Change the User or Job To Adjust Envelope Inserter To Adjust Document Inserter The Setup Screen Explanation The List Box The OMR Code Screen The Barcode Label Screen The Documents Screen The Envelopes Screen The Configuration Screen Configuring the Inserter Inserter Options for Inserter Unit Document Options for Feed Unit Feed Options for Feed Unit Postage Options Output Options Batching Miscellaneous Options The Job Screen The Users Screen The Statistics Screen Running the Job Setting up the Machine Loading the Paper amp Env Hoppers Setting the Separator Gap Operator Maintenance MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus Page 10 12 13 15 17 17 18 19 21 23 25 2 2 28 29 30 32 33 34 35 36 37 41 42 42 43 44 User Manual Part Number K1216A Issue 2 December 2006 Page 1 Maximailer Plus User Manual Datacard H Safety Precautions Observe the following safety precautions at all times when running the Maximailer Plus Be sure you know how to switch the machine off in the event of an emergency This should be done by opening any of the covers Do not try to use this machine until you have read these Operating Ins
15. Maximailer Plus User Manual Datacard 8 Operator Maintenance contd Dual Feeder Open the cover in front of the feeder trays and direct a jet of air onto the sensors shown by the arrows in the diagram below Ensure that all sensors including those inside the pivoting cover are thoroughly cleaned as some sensors are located deep behind the apertures Closer area Open the closer cover below the envelope hopper and direct the jet of air onto the sensors indi cated by arrows in the following view For the sensor pairs liberally spray the air jet in the gap between them MAXIMAILER PLUS OPERATING INSTRUCTIONS Page A7 Maximailer Plus User Manual Datacard 9 Operator Maintenance contd Datacard Turnover Interface On the DTI there are sensors on the cassette and conveyor To access the conveyor sensors raise the top cover and lift the upper conveyot The cassette down and cassette exit sensors are located low down at the cassette side plates They are of the forked type before cleaning rotate the flag clear of the sensot Page 48 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximatier Plus User Manual Datacard amp 9 Operator Maintenance contd 9 3 MAINTAINING THE WETTING SYSTEM The wetter tank supplies the fluid for wetting the envelope flaps and needs topping up from time to time It
16. PLUS OPERATING INSTRUCTIONS Page 37 Datacard View Summary Current amp Previ ous sessions Page 38 Maximailer Plus User Manual 5 8 The Statistics Screen contd Press the Summary button to view the filtered data Note that only valid events will be shown te those that involved documents being fed a machine configuration event for example would not be shown Select from list Start Date Start Time Stop Date Stop Time Run No Job Name 16 06 03 11 05 27 16 06 03 11 06 02 5 stats job2 16 06 03 Oh Fo sobProduction a l a fx 16 06 03 11 STATISTICS SUMMARY 16 06 03 11 Job Name 120mr rev Filled Envelopes 0 Job Date 9 8 2003 Production Output 0 per hour 16 06 03 11 Configuration Erie Production Rate 0 per hour Operator an Job Run Efficiency 0 0 16 06 03 11 Machine Efficiency 4 7 First Run Started 9 8 2003 09 15 51 Filled Envelopes per Groups 16 06 03 11 Last Run Finished 9 8 2003 09 17 59 01 0703 11 Number of Runs 1 Job Run Time 00 02 08 01 07 03 11 Total Downtime 00 02 08 Setting Downtime 00 00 06 01 0703 11 System Running 00 00 00 Operator Downtime 00 00 00 Run Speed 4 Error Downtime 00 02 02 01 07 03 11 Operator Stops 01 07 03 11 Operator Errors OMR Barcode Warnings 01 07 03 12 Machine Errors 01 07 03 12 Total Stops 01 07 03 1273 01 07 03 124 eecng 01 07 03 12 01 07 03 12 010703 13 Select All Oo amp ie ooeoocooce oe S oooo
17. Plus User Manual Datacard 8 Operator Maintenance contd 8 2 CLEANING ROLLERS AND SENSORS Periodically all rollers feed wheels and sensors should be cleaned especially if a long run is envisaged Use only PFE Rubber Riller Restorer Fluid part no E0483A except for the pick up rollers on the feed and envelope hoppers these must be cleaned using only a cloth damp ened with water Clean the full circumference of rubber rollers feed wheels and conveyors in the area of a Feeder and envelope hoppers b Insert area at the head end c Closer area at the head end Ensure the machine is switched off before cleaning rollers or sensors To access rollers in the insert area raise the perspex cover and lift the green handles to reach the paper path Rotate rollers by hand when cleaning To access feeder rollers lower the LH side cover and lift the infill cover in front of the hopper Use the green knob to rotate the rollers for cleaning Note after a long period of time some inserts can cause a jam with the insert stuck between the rollers this may especially occur on coated material If this happens open the upper roller plate with the green latch and using a cloth dampened with Roller Cleaning Fluid clean all the rollers both upper and lower Use the green knob to help rotate them Clean all 12 rollers Cleaning sensors When cleaning the rollers the sensors should also be cleaned by blowing away dust and deb
18. above screen is saved and exited Warning Do not edit the name for a Document currently used in any configuration If you do the factory default document A will be used instead Editing the Icon Select the icon from a preset list this icon that will then appear in the settings eraphic on the Configuration screen see page 27 Form type Select the form type from a preset list Select Card Carrier for all documents from a Card Processor Width Depth Paper Weight Click on the appropriate button and enter the required setting for the form or insert width depth and weight in the units shown see also Thickness amp True Weight on the following page Note width and depth apply to finished ie folded card carrier Thickness If the insert is a booklet or other thick material click the Com puted button to uncheck the box and then click the Thickness button Enter the required figure in mm Note that if this function is used Paper Weight will not be active MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 23 Datacard H Editing the settings contd Notes Maximailer Plus User Manual 5 3 The Documents Screen contd True Weight This shows the weight of the document or insert in the units shown and is linked to Thickness above To enter a known weight click the Computed button to uncheck the box and then click the True Weight button Enter the required figure in the units shown Note
19. acard H Open Archive Page 40 Maximailer Plus User Manual 5 8 The Statistics Screen contd Select Open Archive on the Statistics Diagnostics screen to display the details of archives selected by date Archives are automatically created for each session and are saved on the computer until the end of the current month At the end of the month all session archives are collected into one archive and named as that month and the year For example on the first day of June all session archives for April will be available in a single archive named Apr followed by the year All data up until the end of the month can be seen from the main Statistics screen by pressing Show events data as previously described Archives are stored on the PC of the Maximailer Plus at C Program Files Pfe Maximailer Plus Data Archives DB Select frou lise Mon thly archives ate shown see Daily Archives Faulty Archives ae ar text below for Yalan nfo tor Monthly Archives a Preyer era archive format All Archives Ok X Cancel After selecting the archive press the View event data button to display its contents To return to the data being displayed before the archive was selected press the Current Session button and then the Filter button again the dates originally entered will still be in place Archives are created daily monthly in the format Mmm_yyyy and for faults in the form
20. appropriate password to be entered To view and adjust the settings for the envelope and document inserters click on the relevant part of the machine graphic see the fol lowing page for details MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 11 Datacard fm To change the User To change the Job Page 12 lease select item from list Operator v oy _ lease select item from list c5 all demo 1 2 plate demo 2 2 C5 INSERTS Single A4 wo SESE p5 fa f O nE E E 3 Maximailer Plus User Manual 4 The Run Screen contd Click on the Select User in the logon box to view the list of user To change to a different user click on the name and enter the password you cannot change the user unless you know their password note that the password is case sensitive When changed you will see the new user name at the top of the Run screen To create a new user The Setup Screen must be entered see page 17 Click on the Select Job button to view the list of jobs To change to a different job click on the name and you will see the new job name at the top of the Run screen To create a new job The Setup Screen must be entered see page 17 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard Maximailer Plus User Manual 4 The Run Screen contd To adjust the Envelope Note Click on the Unit button in the top left corner to Inserter settings eee Fins ue se pss
21. at F_mmddyy_n All Other Archives refers to any older or legacy archives remaining on the PC that may be required for later examination All Archives provides access to all of the above shown in one list MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard 6 Running the Job Description of Button Functions Touch the OMR Code button to view all current OMR settings Touch the Bar Code button to view all current barcode settings aa Documents Touch the Documents button to view all current Document settings imal Envelopes Touch the Envelopes button to view all current envelope settings El Configuration Touch the Configuration button to view all current configuration settings Touch the Job button to view all current job settings A Operator Touch the Operator button to view all operator settings A Statistics Touch the Statistics button to view Job Statistics S Engineering Touch the Engineering button to view all current engineering settings E Admin Touch the Admin button to view all current admin settings Aa ion man pe a a Using the Con Now that you have finished defining a configuration it can be associated figuration with a Job Click on Job in the Setup screen and select the configuration as described in the The Job Screen on page 35 Running the When you have associated the configuration with a Job click on Run Job Screen in the Setup screen shown ab
22. box when the Users screen is saved and exited Check the boxes as required to set the roles access levels that are to be allocated the user To provide access to all roles select Superuser For further explanation of the roles contact PFE Technical Support After making any changes click the Save button at the bottom of the screen and then the Exit button to return to the list box MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard 5 8 The Statistics Screen AutoMailer 5 Version 2 0 0 0 Description of Button Functions 2 Touch the OMR Code button to view all current OMR settings aoe Jejeg DJe amp ares ee Current Session 5 Last job Start Date Start time Filter Am4 Test Job perce periGeestorts End Date End time eee Job Last Doc count Last date time Open Archive Operator Hide event data 0 5 27 2004 11 46 20 ___Patatogs O Sumay Event data Qe Touch tH Dae Time JobName Operator Name Evet Faut Code Details Modul Doc Count Speed Stopped by Operator 0 No Fault 0 0 J E 5 27 2004 11 46 19 Am4 Test Job Internal Machine Started 0 No Fault 0 0 9 end Touch th 5 27 2004 11 45 44 Am4 Test Job Internal Stopped by Operator 0 No Fault 0 0 g E 5 27 2004 11 45 42 Am4 Test Job Internal Machine Started 0 No Fault 0 0 3 E 5 27 2004 11 43 41 Am4 Test Job Internal Stopped by Operator 0 No Fault 0 0 9 Touch th E 5 27 2004 11 43 41 Am4 Test Job Internal Machine
23. cessed through the inserter in the same order that they were printed and that there are no missing forms This is achieved by coding each form as it is printed with the alphabetic characters A B C Z The sequence then restarts at A again When the forms are read by the barcode reader any deviation from the correct order is detected and an error produced Set the start character position and whether Incrementing A Z or decrementing Z A Form sequence within a Group As above but A B C Z are printed on each form within the group then repeated for the next group Note if both Job and Group security are used Direction must the same for each After making any changes click the Save button at the bottom of the screen and then the Exit button to return to the list box Page 22 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard i 5 3 The Documents Screen Document Untitled Formlinsert1 Computed Vv Thickness mm From this screen you can edit the Form Insert setup that was selected in the list box see page 18 ot click on New if creating a new setup The setup name and all form or insert parameters can be changed as required Editing the Click on Name and edit the name as required either by typing it or by setup name using the on screen keyboard Any changes made here will be reflected in the Documents list box when the
24. d select the required log as shown below Fens banalo Sa un Docs Output Data Logs Docs Error Data Logs Select from list Docs OCR Data Logs Postages Data Logs All Other Data Logs All Data Logs Event_Russell_ 100703 Event_Russell_ 110703 Event_Russell_140703 __Event_stats job3_010703 txt Event_datalog test_010703 Event_stats job2_010703 Event_stats job3_010703 Event stats job5_010703 Event_stats job6a_010703 Event_stats job6b_010703 Event_sub groups 090703 Event_Russell_ 150703 Event_Russell_ 160703 Event_Russell_ 170703 Event Russell 040803 01 07 03 Event_Russell_ 160903 Event_Russell_ 230903 Event_Russell_ 240903 Event_Russell_040204 Event_Russell_ 050204 Event_Russell_060204 O x Event Data Log file for Job stats job3 Event Dest Docs Event Data stats job3 Started Started Stopped colin Started Started Unit 3 Fault 10 Started Started Stopped Internal Started Started Stopped e00000000000000 SRPRPOORRPORBROOHHSG DOOFMOOMANNOF OAS Points to note 1 Data is logged using only the barcode characters selected in the Barcode screen see page 21 This can be all of the characters a Data Log files are created on the computer disk in the following location C Program Files Pfe Maximailer Plus Data DataLogs For full details of analysing Data Logs see PFE document Data Logging for Automailer 5 MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 39 Dat
25. djust the Note Click on the oa button in the top left corner to Document toggle between fine tuning for unit shown here and Inserter settings hopper shown overleaf The settings available will vaty between feeders and folders Bine PU screen o MNE Click on the feeder or folder Unit e A B a Config Fine Tuning Single A4 display the fine tuning screen Y Hardware Fine Tuning Feeder No fine tuning of the unit part of the feeder is available Document Fine Tuning MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 15 Datacard Maximailer Plus User Manual 4 The Run Screen contd cs Fina oni Se pass Somin Fine Tuning Single A4 a i Fine Tuning Module 5 Hopper 1 7 Hopper Fine Tuning Feeder and Dual Feeder From here you can adjust hopper settings Click on the Unit button and select the appropriate hopper and on Calibrate reader Separator Position A 0 00 Y Hardware Fine Tuning 0 75mm Document Fine Tuning to display further information Document Fine Tuning DL Card 99mm You Can select mem er a Whether the unit is turned on or off Select Off if for example you wish to leave the hopper loaded but temporarily disable it for the job b Whether or not doubles detect is enabled Select Off if for example the documents being run are substantially different from the calibration document such as abnorma
26. e 0 No Fault 0 0 9 H 5725 2004 11 10 58 st3 test 3 Internal Configuration Change 0 No Fault 0 0 9 E 5 25 2004 11 05 37 st3 test 3 Internal Configuration Change 0 No Fault 0 0 3 g Note This screen will only be available to personnel with Supervisor access From this screen you can view information for each event that took place for every job run to date back to the last archive see page 40 for details of archives Your first action should be to filter out data relevant only to what you wish to know as decribed below Filter Press the Filter button and set the filter criteria by date and also by specific job and or operator if required by default all jobs and operators will be assumed Select Custom to choose any start end date or weekly monthly start date Press the date buttons for a calendar lt S 3 A DRAA a E Jalasi Kacgrds Fikar BAR Custom Week C Month l Daily Today 00 00 00 i 00 00 00 Start Date 007 Start Time TRE End Date 00700700 End Time 00 00 00 All Dates Job FO All Operator All Clear Filter Default Jok X Cancel When the required criteria have been set select OK Press the Show event data button for a list of events similar to that shown in the Event Data screen above Note that the button toggles between show and hide You can also view a summary of this information as described on the following page MAXIMAILER
27. eatest OMR Name This function is not available for envelopes Label Name Click this button if you are using barcodes or other labels for verification checking at output then click the Name button and select a label setup see page 21 for defining barcode setups Note that the label can be printed either on the document for reading through the window or on the envelope Click the Save as Default button if you wish this tp be the setup that new documents will default to When all editing is complete click the Save button at the bottom of the screen and then the Exit button to return to the list box MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximatiler Plus User Manual Datacard 5 5 The Configuration Screen Configuration Single A4 Postage Output Miscellaneous Config name Single A4 T r 3 an a 1h Feeder 1h Feeder 1h Feeder 1h Feeder 2pth Folder Fl tw nw 7 7 di card 160gsm DL Card 99mm DL Card 99mm di card 160gsm di card 160gsm i Save As Default From this screen you edit configurations that were created in the List Box after clicking the Con figuration button in the Setup screen see page 17 or click on New if creating a new configura tion A configuration applies the settings to be used for the envelope inserter and all the stations fitted which is then associated with a Job see page 35 You can rename a new configuration by clicking on
28. er Capacity Up to 400 of 80gsm 20lbs bond envelopes General Requirements Envelopes to be good quality machine fill envelope Dimensions and quality to be consistent across manufacture batches Windows to be securely affixed to within 1 5mm 1 16 of top and side edges Top edge to be flat and free from puckering Side seams to be securely glued up to top of seam Position of internal side seams to give a minimum 5mm 3 16 clearance or overlap to the edge of any insert Pre scored flap crease to enable the envelope flap to open flat No twisting curling or distortion evident No glue seepage on interior or exterior of envelope Paper smoothness 100 200 Sheffield units Large printed areas require approval from the Technical Support Dept Envelopes not meeting the above requirements may be acceptable subject to testing and approval by Technical Support Dept Envelopes not meeting the above require ments may affect machine performance MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 5 Maximailer Plus User Manual Datacard H 1 Technical Specification cont General Specification Speed Variable up to 3000 filled envelopes per hour any fold Noise level Less than 75dbA 3 x feeders 1 x DTI measured at 1 6m height 1m from nearest cover excludes noise level of Card Processor Heat Output BTU Hour Rated current x rated volts x 3 412 eg 2354 BTU Hour for typical configura tion of 3 x feeder
29. from a preset list this icon that will then appear in the graphic on the Configuration screen see page 27 Width Depth Paper Weight Flap Click on the appropriate button and enter the required setting for the envelope s width depth weight in the units shown and flap length see also Thickness below Thickness If the envelope is of very thick material or of unknown weight click the Computed button to uncheck the box and then click the Thick ness button Enter the required figure in mm Note that if this function is used Paper Weight above will not be active MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 25 Datacard H Editing the settings contd Page 26 Maximailer Plus User Manual 5 4 The Envelopes Screen contd True Weight This shows the weight of the envelope in the units shown and is linked to Thickness described on the previous page To enter a known weight click the Computed button to uncheck the box and then click the True Weight button Enter the required figure in the units shown Note that if this function is used Paper Weight will not be active The true weight need only be entered if Postage Rates are being used see page 33 Amount of wetting required Different envelope types may require a greater or lesser amount of wetting for an effective seal If you wish to change from the default setting of 3 click the appropriate button where setting 1 is the least 4 is the gr
30. g margin mm Trailing margin mm Mark threshold v Divert oversize group Divert blank sheet Address on every page Invisible gate mark Ba sav IE Exit From this screen you can edit the OMR setup selected in the list box see page 18 or click on New if creating a new setup The setup name and all OMR settings can be changed as required Editing the setup name Editing the settings MAXIMAILER PLUS OPERATING INSTRUCTIONS Click on OMR Name and edit the name as required either by typing it or by using the on screen keyboard Any changes made here will be reflected in the OMR Code list box when the OMR screen is saved and exited Warning Do not delete an existing setup if it is used in a current job If you do the factory default will be substituted Set the Number of marks Direction Parity First mark position according to the marks you are using and their printing on the stationery Security Count direction and Security Count start whether 0 or 1 Note that Fixed is currently the only available option for pitch Also set the Pitch Read channel see below Gate position from TOF Leading amp Trailing margins allowable tolerance for printed mark set to drift and still be read Mark threshold decrease if print quality of marks is poor increase if background is dark Divert oversize group Y N Divert blank sheet Y N Address on every page Y N and Invisible Gate Mark Y N thi
31. he edge of the side seam it is liable to catch making it twist This will cause insertion problems Non standard feed wheels are available in different materials and geometries These can prove effective to overcome slow feeding on some inserts contact Technical Support for details Page 4 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard age Maximailer Plus User Manual 1 Technical Specification cont Envelope Specification T SR ae Min 10mm i 7 Minimum open ee C1342 Flan Lenoth jo throat area N P 8 i N Flap Shoulder Angle Min i Throat angle Maxa rani N 50 Min 90 Max in 5 Min 20 Max Min Seni J L CAA y J Le A Body Depth Min 70mm 234 Tal 8 Min 89mm 3 Horizontal portion of throat Min 10mm 349 Max Envelope Width 75mm 3 side Seam style envelope Envelope Width Max 264mm 10 Min 178mm 7 a throat area si 752 M g 50 Pii Flap Shoulder Aniel Min Throat angle axiom ote T a ea Bee 10mm J 5 Min 20 Max Min 32mm 114 i 50 Min 90 Max 340 i i i Body Depth B Min 70mm 234 Max 165mm 6 4 oaa a Min 89mm 3 5 Horizontal portion of throat emer Max Envelope Width 75mm 3 eae Commercial style envelope Envelope Width Max 264mm 1034 Min 178mm 7 Envelope Weight 70gsm 18lbs bond min 100gsm 26lbs bond max Hopp
32. he prime unit See page 39 for further details of datalogs This allows you to select the unit that carries the address document usually the prime unit Note this can also be selected from Feed options for feed unit see page 30 Whichever is set the later takes precedence Select No if you wish the machine to continue running after a calibration cycle is performed by defaut machine will stop and await confirmation of envelope contents After making any changes click the Save button at the bottom of the screen and then the Exit button to return to the list box b MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard ZA parcodesiabels Documents Envelopes ET configurations E sons Q users E Statistics E Engineering E Admin Maximailer Plus User Manual 5 6 The Job Screen Job Untitled Job1 Current settings Job name Module 0 Hopper 1 Envelope Default Seal Mode Alw Untitled Job1 no Module 1 Hopper 1 Document Default Feed Control Mode Feed always Configuration Module 2 Hopper 1 Document Default Feed Control Mode Feed always Module 3 Hopper 1 Document Default Feed Control Mode Feed always Module 4 Hopper 1 Document Default Feed Control Mode Feed always Module 5 Hopper 1 Document Default Feed Control Mode Feed always Module 6 Hopper 1 Document Default Feed Control Mode Feed always Module 6 Hopper 2 Docume
33. ift etc Multiple insertions may also be used ie a preset number of forms are separately fed onto the insert track each time the feed unit is called There is a batch processing facility allowing a preset number of cycles to be completed before the machine automatically stops The machine consists of a number of modules depending upon the build ordered these modules are briefly described below a Inserter head Collates all documents in a pocket before insertion feeds the enve lope inserts the pack and seals the flap b Insert Feeder Feeds shortform inserts cards cheques booklets etc onto the track for subsequent insertion Available as a single feeder with one feed hopper or a tower feeder with two feed hoppers An OMR Barcode version with one feed hopper is also available c Datacard Turnover Interface Receives a folded card carrier from a Card Processor turns it over to orientate the address correctly and feeds it onto the track for subse quent insertion The Maximailer Plus is equipped with PC controlled operating software from where jobs can be programmed and run Jobs can be quickly switched from the main screen and can also be fine tuned to accommodate a small change in job requirement The number of jobs that can be programmed is limited only by the capacity of the PC Input is via touch screen monitor or keyboard mouse No manual setting of the fold plates or envelope closer is required these bei
34. is closed without sealing Deskew The setting of the amount of envelope deskew required Note a higher level will slow the machine more Item ID If available for setting must be set to Item ID 1 Page 28 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard 5 5 The Configuration Screen contd Setting the Click the upper icon on one of the numbered units showing the document document op icon This displays the list of available documents to select see page 23 for tions for the creating documents If the list is long a Find box will appear to enable Feed unit you to search the list using keywords If more than one incidence of the search result occurs the Next and Previous buttons will be active i ETES Select the required document and click Ok Note An error will occur if a document that is used in any configuration has been deleted from the list box in the Setup scteen see page 18 MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 29 Maximailer Plus User Manual Datacard 5 5 The Configuration Screen contd Setting the feed Click on the lower icon of the numbered feed unit showing the unit icon options for the and the following dialog box appears Feed unit Moule a rleuusr il Note that the a pa laa aE neta options in the dialog box may vary from those shown de pending on whether the unit is a feeder ot a folder
35. is located on the left hand side of the machine below the closer area at the output To gain access lower the side cover on the insert head Fill the tank through the spout until the level reaches the indicator visible inside be careful not to overfill Note Use only PFE Envelope Sealing Fluid A0276A as this has been specially formulated for greatly enhanced sealing and antibacterial qualities Fill through the spout as shown up to the level indicator Withdraw the tank by using the green tab Check the condition of the sponge at regular intervals and clean off gum residues as re quired Remove the wetter tank to do this by lifting the end slightly using the green tab then withdraw it Note use a piece of absorbent material to under the drain tube to catch any drips Clean the sponge under running water and replace the tank ensuring it is fully located After cleaning or if the sponge has dried out it should be primed by immersing it in Envelope Sealing Fluid lf the machine is to be left unattended for more than a week it is advisable to remove the tank and drain it Wipe dry after washing to prevent contamination The tank must also be removed if the machine is moved and the reservoir drained The reservoir can be drained by pulling out the plastic drain tube tucked under neath it and pulling out the bung to drain into a suitable receptacle MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 49 Maximailer Plus User Manual
36. lect Save as Default to make this the default for all new postage setups Setting the weight group thresholds Setting the postage rates Page 32 Maximailer Plus User Manual 5 5 The Configuration Screen contd Ensure that the Postage tab in the configuration screen is selected This section allows you to define weight groups for setting different postage rates The filled envelopes can then be diverted to different locations according to the weight range that they fall within If you will not be using postage rates these settings can be ignored Note This screen will only be available to personnel with Supervisor access Configuration Russell OMR N Weight Group Thresholds amp Postages Z weight Group 1 g oso to 0 00 Sf gt weight Group 2 a oso 100 Sf weight Group 3 9 100 to 2 00 Weight Group 4 g 200 to 250 00 te save As Defaut Save S exit There are four weight groups each one defining a range with a lower and upper weight and a postage rate to be set for that range The upper weight that you set for each group will automatically appear as the lower weight for the following group enabling an ascending scale of postage rates to be set for the four groups To set the threshold for the first group click the Weight Group 1 button and enter the upper weight of the range in grams Press Enter To set the postage rate for Group 1
37. lly dark with heavy printing c Separator Position if you select a different setting from the one displayed as calculated by the software ensure the physical separator is set to the same setting or a warning will be flagged with the first insertion cycle only Note this setting is duplicated in the Configuration screen see page 30 Whichever is set most recently takes precedence d The setting of the amount of document deskew required Note a higher level will slow the machine more e Calibrate Reader Only available if OMR head is fitted Click the button and follow the instructions for calibration f Reader On Off Only available if a barcode head is fitted Switching the reader on or off is required when aligning g Click on the button and adjust width and depth if actual document varies from the settings shown Warning if the same document is used on other jobs as well the same settings will be applied Important All fine adustments apply only to the current job and will not affect any other jobs Page 16 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard The Setup screen ex plained p Maxia Mu Version 26 9 700R Maximailer Plus User Manual 5 The Setup Screen From this screen you make changes to the machine setup Changes can then be saved and will remain until they are changed again To enter the screen click the setup button 6 on the Run screen E C a OMR Code Bar Code
38. ly set see page 43 contact the Service Department Dual feeder amp OMR Feeder If a paper crash occurs this is most likely to be at the eject sensor at the exit To clear the jam it can be awkward to pull the paper out if raising the roller catrier at the exit An easier method is described below 1 Lower the operator side cover of the dual feeder and of the feed unit in front if the unit in front is the insert head raise the perspex covet 2 Use the green knob on the feed Insert head and feeder Raise the top perspex cover and small feeder cover Lift the green latch bars as shown to access the paper paths below Carefully withdraw any jammed paper taking care not to tear it To clear a crash in the feeder lower the feeder side cover and swing the green handles upwards to access the paper paths If necessary use the green knob to turn the shafts for winding out jammed paper If a jam occurs at the input of the envelope or feeder hoppers remove all material and withdraw the jammed item For feeders ensure that the For the envelope hopper if jams occur frequently unit in front to swing down the lower conveyor or raise the rearmost clam assembly if the unit in front is the insert head 3 Turn the green knobs on the dual feeder to wind the crashed document into the cavity ahead it can then be easily removed Page 44 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer
39. machine mote Item ID Options are Auto Nos 2 17 Use Auto unless select feed marks are being read Item ID then allows a number to be assigned to each unit to identify with the select feed mark Page 30 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard f 5 5 The Configuration Screen contd Default Separator Position Only available on feeder or dual feeder and is a read only display Indicates the separator position calculated by the software If the physical separator is set differently from this a warning will be flagged for the first insertion cycle only Separator Position Only available on feeder or dual feeder If you select a different setting from the one displayed in Default Separator Position see above ensure the physical separator is set to the same setting ot a warning will be flagged with the first insertion cycle only Note this setting is duplicated in the Fine Tuning screen see page 16 Whichever is set most recently takes precedence Cascading Feeds from previous or next unit if feeder runs out of inserts Settings available will depend upon hardware fitted and location of hopper Above and Below apply to multi hopper units Left and Right apply to single hopper units as viewed from the operator standpoint MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 31 Datacard Setting the postage options EY Configuration Se
40. ng adjusted automatically according to the settings in the selected program MAXIMAILER PLUS OPERATING INSTRUCTIONS Page T Datacard H8 Maximailer Plus User Manual 2 Machine Layout Guide cont 2 2 PARTS IDENTIFICATION PC control Insert collate pane Dual area feeder Standard feeder Datacard Turnover Envelope Interface hopper Closer area Opening side covers Output see below Note Station 7 is the first feed unit after the insert collate area Filled envelopes may be output Storage cupboards PC into a receiving tray or onto an under insert head optional conveyor Page 8 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard What s in this Document On line Help Maximailer Plus User Manual 3 About this Document This User Manual guides you through the stages of using the Maximailer Plus The machine is entirely software controlled with all operator func tions being performed on the touch sensitive control screen Different levels of user access can be allocated to personnel so that for example configuration operations can be restricted to Supervisors while operators will only have access to straightforward running of the machine The sections of this document that relate to restricted access are clearly The Operating Steps The functions described in this document are The Run Screen from which you control the running of the machine The Setup Screen where
41. nt Default Feed Control Mode Feed always Module 6 Hopper 3 Document Default Feed Control Mode Feed always Module 6 Hopper 4 Document Default Feed Control Mode Feed always fa sav E Exit From this screen you can edit the job that was selected in the list box see page 18 or click on New if creating a new job The job name can be changed and or a different configuration associ ated with it Editing the job name Selecting a configuration Logging OCR data Late divert Checking Click on Job Name and edit the job name as required either by typing it or by using the on screen keyboard Any changes made here will be reflected in the Job list box when the Job screen is saved and exited Click on Configuration and select an existing one from the list if any To create a new configuration see The Configuration Screen on page 27 Note A configuration can be associated with as many jobs as you wish Click on Log OCR data if you are using an OCR scanner on the output and need to log the data gathered Select On CommPort if you wish to log data via the PC port Select Display verification read to display data on the Run screen as well as log to file The file will be stored in the Data DataLogs directory on the hard disk and will take the format oct_ lt Jobname gt _ lt Date gt txt ocr will vary for different data types Set this to Yes to use customer
42. nvelopes into the pickup roller the side guides to An alternative heavier roller is also available part no C3656A which give 1 2mm can improve feeding of thick booklets This must be fitted by a PFE clearance across Service Engineer the width of the envelopes Tighten the lock lever Page 42 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard 7 Setting up the Machine contd 7 3 SETTING THE SEPARATOR GAP The feeder separator has 4 settings marked A to C on the slide Before running the job the gap must be set to suit the thickness of material being processed this prevents more than one item being fed at a time Note that there is an intermediate setting between each marked position allowing finer adjustment Slide positions A 0to0 5mm B 0 75 to 1 5mm C 1 5 to 2 5mm D 2 5 to 4 0mm A C only on Tower Feeder Lower the side cover and move the slide to suit the thickness of the insert Most jobs will use position A If you use the wrong setting an error will appear on the control panel MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 43 Datacard 8 1 CLEARING PAPER CRASHES Maximailer Plus User Manual 8 Operator Maintenance If a paper crash occurs the machine will stop and indicate the position of the crash on the screen Clear the crash as shown below then press the Run button to resume operating separator gap is correct
43. ocument click None Click the Save as Default button if you wish this to be the setup that new documents will default to When all editing is complete click the Save button at the bottom of the screen and then the Exit button to return to the list box 1 Minimum document width in the pack including inserts must be no smaller than the maximum document width by more than the following Minimum docu ment width Maximum document width 2 58mm eg if maximum document 210mm minimum document width 210 2 58 163mm minimum Page 24 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard Paper Weight gsm Flap mm Maximailer Plus User Manual 5 4 The Envelopes Screen Envelope DL Plus1 Ba sav IE Exit From this screen you can edit the Envelope setup that was selected in the list box see page 18 or click on New if creating a new setup The setup name and all envelope parameters can be changed as required Editing the setup name Editing the settings Click on Name and edit the name as required either by typing it or by using the on screen keyboard Any changes made here will be reflected in the Documents list box when the Documents screen is saved and exited Warning Do not edit the name for an Envelope currently used in any configuration If you do the factory default document DL will be used instead Icon Select the icon
44. orcoo oeeoeccoc cs ooocoioce Se o oooocooceco oe oeoocooeccoe oeecoecoeoc oe i 3 Select an event and press OK to view the summary as shown above Note that you can also select more than one event by selecting the first in a range holding down the shift key and then selecting the last in the range Alternatively all events can be selected by pressing the Select All button If a printer is connected the summary can be printed by pressing the Print button The data will be collated and printed in portrait format Press the Current button to view only the events that have occurred since last logging on The Previous button shows events up to the last new logon If a new archive is opened see page 40 the Previous button will restore the events that were displayed prior to its opening continued overleaf MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard Maximailer Plus User Manual Data Logs Data Logs are created automatically whenever the machine is run A separate log is created for Events Document Outputs Errors OCR data where applicable Postage and Others as yet undefined These are text files and are named according to their type followed by the jobname and date see example below If a job is finished then returned to later the same log files will be added to even if another job had been run between the two runs To view the logs press the Data Log button an
45. ove This will return you to the Run screen where you can commence operating as described in The Run Screen on page 10 Before running the job ensure that the machine is loaded with stationery and is properly set up see Setting up the Machine on page 42 Note A configuration can be associated with as many jobs as you wish MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 41 Maximatiler Plus User Manual Datacard 7 Setting up the Machine 7 1 LOADING THE PAPER HOPPERS Pull the weighted roller back and load the Insert Feeder Single Dual OMR Barcode inserts ensuring they are fully down Release the weighted roller so that it tips the inserts into the pickup roller An alternative heavier roller is also avail able part no C3656A which can improve Slacken the lock feeding of thick booklets This must be lever and adjust fitted by a PFE Service Engineer the side guides to give 1 2mm clearance across the width of the inserts Tighten the lock lever Note A single feeder is shown if the unit is a dual or OMR Barcode feeder the method of loading is identical but the hopper capacities are different see Technical Specification on page 3 7 2 LOADING THE ENVELOPE HOPPER Pull the weighted roller back and load the envelopes ensuring they are Slacken the lock fully down flaps must be facing forwards Release the weighted roller lever and adjust so that it tips the e
46. quantity either by typing it in or using the on screen keyboard For Control mode select Auto restart machine will pause for a set length of time and then restart see below for Pause time or Pause machine will stop and will only restart when the Run button is pressed Jog step allows a gap between envelope batches to be set on the conveyot The units shown are multiples of the envelope overlap as adjusted by the knob on the conveyor This means a suitable gap can be set without disturb ing the knob Pause time is the number of seconds before the machine auto restarts After making any changes click the Save button at the bottom of the screen and then the Exit button to return to the list box MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 33 Datacard fm Setting the miscellaneous options Setting the datalog unit Address Carrier Confirm calibration Page 34 Maximailer Plus User Manual 5 5 The Configuration Screen contd Ensure that the Miscellaneous tab in the configuration screen is selected This section allows you to select the required station for data logging where used and also for the address carrying document Note This screen will only be available to personnel with Supervisor access Configuration Untitled Config1 If you are using datalogs set the unit you wish to use to record the log from by pressing Logging from By default this will be t
47. ris using the supplied airduster It is important that sensors are regularly cleaned or operating errors may occur Locations are shown on the following page note that each sensor is in two halves receiver and transmitter Both halves must be cleaned Use only non flammable airdusters such as supplied by PFE part no A0070A MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 45 Maximatiler Plus User Manual Datacard 8 Operator Maintenance contd Cleaning sensors contd Insert and collate area For all positions shown direct the jet of air onto the sensors indicated by arrows in the following views Note that sensors are in two halves receiver amp transmitter both halves must be cleaned Open the perspex cover and front feeder cover then lift the front most green handle to raise the mechanism this is held in the raised PER position by a latch For the sensor pairs liberally spray the air jet in the gap between them Feeders Lower the feeder side cover and raise WIDTH UPPER ij the top cover Swing the green latch upwards to raise the roller platten Note station 1 feeder is shown others are similar yn S A N S a x ae a INA NN IS ne 7 NS A vo COYLIT AL AL De NOS 3 SA XSAN ONY Y Page 46 MAXIMAILER PLUS OPERATING INSTRUCTIONS
48. s DTT excludes heat output of Card Processor Heat Output Watts Rated current x rated volts eg 690W for typical configuration of 3 x feeders DTT excludes heat output of Card Processor Electrical 230VAC 115VAC Frequency 50Hz 60Hz Input Current Head 1A Head 2A Feeder 0 5A Feeder 0 57 Dual Feeder 0 5A Dual Feeder 0 5A OMR Feeder 0 5A OMR Feeder 0 5A DTT 0 5A DTI 0 5A Fuse Rating T6 3A T10A Insert Head Weights nett Inserter Head 56Kg Feeder 25Kg Dual Feeder 44Kg DTI 25Kg Page 6 MAXIMAILER PLUS OPERATING INSTRUCTIONS Maximailer Plus User Manual Datacard 8 2 Machine Layout Guide 2 1 DESCRIPTION OF MACHINE The function of the Maximailer Plus is to feed forms from a Datacard Card Processor and or a number of hoppers fold them in either C Z V or double forward fold where required and insert them into an envelope which is then sealed and ejected The folded card carrier is supplied from the Card Processor via an interface which turns it over before feeding it onto the track the document will then be orientated correctly for the address position Further inserts cards cheques etc may optionally be collated with the card carrier by collating on the track All documents are then gathered in the collation pocket at the inserter head for insertion as one pack into the envelope Forms may be inserted without sealing the envelope eg for subsequent hand insertion of card g
49. s ve further forward into the output rollers towards the exit direction When all adjustments are complete click on the Unit button for hopper settings as described opposite Important All fine adustments apply only to the current job and will not affect any other jobs MAXIMAILER PLUS OPERATING INSTRUCTIONS gt Page 13 Maximailer Plus User Manual Datacard H 4 The Run Screen contd Hopper Fine Tuning Fine Tuning screen Unit Fine Tuning Module 0 Hopper 1 Config Fine Tuning Single A4 From here JOu var adjust Sette tas o Ropper sertings Click on the inserter hopper then Docu ment Fine Tuning to display further information You can Hardware Fine Tuning Document Fine Tuning DL PlusPlus 121mm select a Whether or not the envelope is sealed Select Off if for example later hand insertion of an insert or other item will be required b The setting of the amount of envelope deskew required Note a higher level will slow the machine more c Click on the button and adjust width and depth if actual envelope varies from the settings shown Warning if the same document is used on other jobs as well the same settings will be applied Important All fine adustments apply only to the current job and will not affect any other jobs Page 14 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard Maximailer Plus User Manual 4 The Run Screen contd To a
50. s allows use of a single mark as End of Group Channel number this is assigned to the OMR head according to its connection on the machine s PCB Ensure you are using a channel number for which has a connection exists default for 1 head is channel 1 Page 19 Maximailer Plus User Manual Datacard H 5 1 The OMR Code Screen cont Now click on each OMR mark position button and enter the type of mark for each position according to the marks you are using Note Prior to running a new or edited OMR setup the machine must first be calibrated using a calibration sheet see note below The results of the calibration will be shown on the screen for each selected OMR unit After making any changes click the Save button at the bottom of the screen and then the Exit button to return to the list box Note For full details of OMR specifications and calibration see PFE document Specifications for Maximailer Plus Page 20 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard i Maximailer Plus User Manual 5 2 The Barcode Label Screen Bar Code Untitled BarCode1 E OT GOOR Form and Envelope Divert 3 Data log characters Last page Data logging characters startpos a Customer ID characters 1 From this screen you can edit the barcode or other ID label setup selected in the list box see page 18 or click on New if creating a new setup The se
51. that if this function is used Paper Weight will not be active The true weight need 2 only be entered if Postage Rates are being used see page 33 Pre Folded Leaves If the insert consists of more than one leaf eg a 2 folded flyer click the button and enter the number of leaves OMR Name Click this button if you are using OMR then click the Name button and select an OMR setup see page 19 for defining OMR setups Label Name Click this button if you are using barcodes or other labels then click the Name button and select a label setup see page 21 for defin ing barcode setups Document ID Used to verify that the correct stationery is loaded into the correct feed unit If using this feature set Doc ID Mode to ON and define the alpha numeric characters being used for the ID Note that the start position and length of the characters must be set in the Barcode Label screen See also Barcode Specification for Maximailer Plus for a full de scription of Document ID Document Address If this is the address document click the Address Position button and select the position that best describes the location of the address this will be used by the software to determine the type of fold and orientation of stationery Note that the left right location of the ad dress is not stated as this will be determined by the printed address match ing the lateral position of the envelope window If it is not the address d
52. the New or Edit buttons are clicked the edit screen for that particular setup is dis played These are explained in detail on the page indicated below List Box OMR Code Page 19 Bar Code Page 21 Documents Page 23 Envelopes Page 25 Configuration Page 27 Job Page 35 Users Page 36 If any changes are made to the list box ie if an existing item is copied or deleted the Save button will be active Click on this to save the changes and click Exit Note that if an item is edited any changes will be saved on that particular edit screen and the Save button will remain dimmed Warning For the OMR Code Bar Code Documents and Envelopes list boxes do not delete a setup that is currently used in any configuration If you do the configuration that uses the setup will be substituted with the factory configuration named Default Config which cannot be deleted or edited for further details of Configurations see page 27 Page 1 8 MAXIMAILER PLUS OPERATING INSTRUCTIONS Datacard Maximailer Plus User Manual 5 1 The OMR Code Screen OMR Code Untitled Omr1 Untitled Omr1 OMR Code name Number of marks Ly Barcodes Labels Fixed pitch You Direction Forward Parity Off Security count direction Security count start A Configurations Pitch A Documents Incrementing imal Envelopes E Jobs A Users A Engineering A Admin Read channel Gate position mm Leadin
53. tructions and are fully conversant with its operation Keep loose clothing long hair and jewellery clear of all moving parts Do not touch any moving parts When opening the covers ensure that all moving parts have come to a halt before touching them Do not attempt to dismantle any part of the machine or remove any fixed covers this could result in risk of electric shock or fire If service attention is required call a PFE authorised Service Engineer When cleaning sensors use only non flammable airdusters such as supplied by PFE part number E0070A Other types may use flammable propellants which could result in fire or explosion If damage to any cover has occurred it must be replaced by a PFE authorised Service Engi neer If any access cover safety switch fails allowing the machine to continue operating when the covet is opened call a PFE authorised Service Engineer immediately Do not cover any vents or openings or overheating may result Avoid placing piles of stationery or other objects on top of the machine they could topple off and create a hazard Do not attempt to operate the machine with stationery outside the limits shown in the specifi cations Ensure you have free access all round the machine for loading paper hoppers etc Do not place surrounding furniture or other objects where your path may be obstructed PUT SAFETY FIRST Page 2 MAXIMAILER PLUS OPERATING INSTRUCTIONS
54. tup name and all label settings can be changed as required Editing the setup name Editing the settings for non BCS char acters Click on Barcode name and edit the name as required either by typing it ot by using the on screen keyboard Any changes made here will be re flected in the Barcode list box when the Barcode screen is saved and exited The buttons below Name relate to label settings and other non BCS char acter functions These are briefly described below Number of characters in label Up to max 20 for PFE BCS system Label machine control Available control systems are PFE BCS default and any other available Custom Control For all except PFE BCS PFE Technical Support department must be consulted Grouping Select whether the group mark is End of group First of group ot Label on first page only label printed on first page of group but not subsequent pages Good decode reads Set the maximum number of good reads required before label is accepted Set to low number if print quality is poor Security check Used as a further method of security checking additional to or instead of using security BCS character Select the character type to be used for checking gt MAXIMAILER PLUS OPERATING INSTRUCTIONS Page 21 Maximailer Plus User Manual Datacard 5 2 The Barcode Label Screen contd Data log enabled If selected a record of the movements of each group will be retained in a log file
55. which can be viewed later in the Statistics screen This data can then be used to compare the original number of documents with the number of processed envelopes Choose whether to log from the label on the first page of a group or the last For details of Data Logging and the Statistics screen see page 37 Divert oversize group If set to Yes groups that are too large to fold will be fed into the divert tray if fitted without stopping the machine If no tray is fitted the machine will stop with the group in the accumulator Divert blank sheet As above but applying to sheets with no label Data logging characters If data logging is being used click on and enter the start character position and number of characters See also page 37 Customer ID characters Customer ID can be used for grouping as an alternative to the Grouping character Each form within a group is printed with the same character s with each group using a different character s Editing the Click on and enter the start position and character length of each function settings for either by typing it in the Enter Value box or by using the on screen BCS characters keypad Number 1 is the first mark from the leading edge O zero means that character is not used Note a minimum of 4 characters must be used See also Barcode Specification for Maximailer Plus Security Form sequence within a Job This is used to ensure that forms are pro

Maximailer Plus - Neopost Technologies Ltd

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