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DS-140 user guide

1. Feed unit box will appear to enable 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 Letter Select the required document and DL Card 99mm click Ok Si BRE One 3rd Letter folded Half Fold Letter A5 Insert Jan_draft_A4 Jan_draft_itr c Note An error will occur if a document that is used in any configuration has been deleted from the list box in the Setup screen see page 19 31 5 7 4 Setting Click on the lower icon of the numbered feed unit showing the unit the feed icon and the following dialog box appears options for the Feed u nit Moduls Ji Ji Feeder rlouper J7 Moduls sridard fouuer Module standard hopper EE DL Card 99mm Please select and modify settings C Note that the options tii in the dialog box may Feed Control Mode Feed always vary from those shown depending on whether the unit is a feeder or a folder C amp Select Save as Default to make this the default Separator Position A 0 00 0 75mm for all new setups These ese ae settings then apply to Load Default 32 Mark Reading Thickness doubles Deskew Address Carrier Select whether or not this is the address document Note this can also be selected from Miscellaneous see page 37 Whichever is set the later takes precedence Feed Control Mode Options are Off Feed Alw
2. amp Other paper orientations are possible for non standard envelopes see Appendix A for details When you have finished running daily post Press the stop button as normal 45 8 SETTING UP THE MACHINE 8 1 Loading the paper hoppers Insert Feeder Single tower OMR Barcode Slacken the lock lever and adjust the side guides to give 1 2mm clearance across the width of the inserts Tighten the lock lever Tower Folder amp Feeder folder Slacken the lock lever and adjust the side guides to give 1 2mm clearance across re the width of the forms Tighten the lock lever 46 Pull the weighted roller back and load the 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 available part no C3656A which can improve feeding of thick booklets This must be fitted by a Service Engineer Note A single feeder is shown if the unit is a tower or OMR Barcode feeder the method of loading is identical but the hopper capacities are different Press down on the tray and load the fanned stack of forms Ensure that the leading edges are firmly contacting the chassis bridge at the lower end of the tray Use the indicator lights on the rear edge to orientate the paper amp 1 Tower folder is shown feeder folder is similar except only 1 tray is fitted and there is no i
3. Security count direction Mark at position 6 Mark at position 7 Security count start Mark at position 8 Pitch Gate position mm Leading margin mm Trailing margin mm Divert oversize group Divert blank sheet Address on every page Gl Save 9G Exit From this screen you can edit the OMR setup selected in the List Box 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 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 Definition mode see below Code type 1 track or 2 track Number of marks Gate position which edge of the paper the gate mark is parallel to in relation to the address 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 Definition mode Options are As printed As fed If As printed the software will adjust for the mark direction whicheve
4. Simm S Ce matmens OO o raptores O O e maeneene O o id eserim emoostonemn SSS mantemos O OOO o c Note Click on the Unit button in the top left corner to toggle between fine tuning for unit and hopper 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 envelope 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 rollers ve further forward into the output rollers towards the exit direction When all adjustments are comple
5. When some action is expected from the operator this will always be explicitly stated and where relevant accompanied by an illustration or graphic Always read through each step so that you will obtain all of the necessary information Do not anticipate what you believe will follow in the handbook It will prevent you from making mistakes Chronology and Reference This handbook is structured chronologically and therefore ordered sequentially for the operationally ready machine It assumes that the machine has been installed in the correct environment by an Authorised Service Engineer and that the operator or his or her supervisor has had a degree of operator training When you are unfamiliar with the machine it is best to read through the handbook from beginning to end You will be guided step by step and in this way you can easily and quickly have the machine in operation If you are already familiar with the machine it will make thing easy if you use this handbook as a reference work 2 SAFETY NOTES For your own Safety and the operating safety of the machine read the following notes carefully before starting your machine Always be aware of all warnings and notes that are mounted or noted on the machine itself Save this handbook carefully so that the information it contains may be available at all times The machine is of advanced construction and reliable in operation Nevertheless the device does present hazards when oper
6. 3 4 To adjust the Document Inserter settings 08 17 5 4 The Setup screen 1 0 2 ccc eeeeee ee eeeeen eee eee e eats e neta ed 19 5 4 1 The Setup screen explained ccceceeece eee eee eee e teens 19 5 432 The List BOX a w tau ae iar wh a de eat 20 5 5 The OMR Code SCreen 0 2 cc cceee eee ee ee eee eee eee eee e eee eee e eaten eed 21 5 6 The Barcode Labels screen ccceeeee eee ee eee e tees eee e etna teeta eed 23 5 7 The Documents SCre N ccceee cece eee eee teens eee eee eee tae tate teed 25 5 8 The Envelopes screen cccecece eee ee cece cena eee etna eee ne teeta eneenees 27 5 9 The Configuration SCre n c cece cece eect eee nett nena e nett eee 29 5 9 1 Configuring the inserter cece cece eee e eee ee eee ee eae 29 5 9 2 Setting the inserter options for the Inserter unit 30 5 9 3 Setting the document options for the Feed unit 31 5 9 4 Setting the feed options for the Feed unit 0000e ee 32 5 9 5 Setting the module options for a Folder 34 5 9 6 Setting the output Options cece eee eee eee eee teens 35 5 9 7 Setting the postage Options cecceee eee ee eee ee eee eaten 36 5 9 8 Setting the miscellaneous Options cece cece e eee ee eee 37 5 10 The JOD SCrEGN ccc eee cece cece eee ee ences eeeeeeeeeeeeeseeeeneeeneeeeeeneeaes 38 Sll The Users Sereen crire aeea aaa 39
7. Archives provides access to all of the above shown in one list 43 6 RUNNING THE JOB OS E OMR Codes Barcodes Labeli Description of Button Functions Touch the OMR button to view all current OMR settings Touch the Barcode button to view all current barcode settings Security Archive data Touch the Envelopes button to view all current envelope settings Languages Touch the Documents button to view all current Document settings Touch the Configuration button to view all current configuration settings CE Statistics Touch the Job button to view all current job settings Touch the User button to view all current user settings Touch the Statistics button to view Job statistics Engineering Touch the Engineering button to view all current engineering settings Admin x Run Screen Touch the Admin button to view all current admin settings Using the configuration Now that you have finished defining a configuration it can be associated with a Job Click on Job in the Setup screen and select the configuration as described in the The Job Screen on page 38 Running the Job When you have associated the configuration with a Job click on Run Screen in the Setup screen shown above This will return you to the Run screen where you can commence operating as described in The Run Screen on page 13 Before running the job ensure that the machine is loaded with stationery and
8. SySteM ccee cece ee eee eee eee teeta eed 56 Document Orientation Tables cc ccecseeeeseeeeeeeeeeeeeeeeeeeeeeeeeennanes 57 1 INTRODUCTION With this inserter you have an advanced medium volume folding and inserting machine Its modular construction allows up to 8 feed units to be fitted with a maximum of 17 feed trays Its sophisticated software control optimises the order and flow of documents for collating at the insert head before insertion into the envelope All fold and adjustments take place automatically according to the requirements programmed in by the operator In order to ensure the long usage of this machine and its components and above all the safe use of the machine you must read and adhere to the operating instructions and safety notes Always be aware of all warnings and notes that are mounted or noted on the machine itself All persons entrusted with the handling of this machine must also be familiar with the operating manual Save this handbook carefully so that the information it contains may be available at all times 1 1 Pictograms AN General Warnings A N Warning of danger from electricity or electrical shock Ee Information Note indicating important information regarding the handling of the machine 1 2 Notes on the Use of this Handbook This document contains all general information and explanatory text necessary in order to be able to carry out the operation of the machine
9. criteria such as a keyword or a part of it When either the New or Edit buttons are clicked the edit screen for that particular setup is displayed These are explained in detail on the page indicated below A5 Insert 109 Insert 160 113 4 Find tame 4 Find iD List Box OMR Code Page 21 Barcode Labels Page 23 Documents Page 25 Envelopes Page 27 Configuration Page 29 Job Page 38 Users Page 39 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 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 29 20 5 5 The OMR Code screen OMR Wk 44_1 Please edit avalaible and accessible settings if neccessary OMR name Wk 44 1 OMR mark position st 5 Mark at position 1 Definition mode As printed Mark at position 2 Code type 1 track Mark at position 3 Number of marks Mark at position 4 Gate position Mark at position 5 Parity
10. ensure the operational safety of your machine 2 2 End of Life The objectives of the European Community s environment policy are in particular to preserve protect and improve the quality of the environment protect human health and utilise natural resources prudently and rationally That policy is based on the precautionary principle and principles that preventive action should be taken that environmental damage should as a priority be rectified at source Separate collection of waste is the precondition to ensure reuse and recycling of waste that is generated at the disposal of electrical or electronic equipment and is necessary to achieve the chosen level of protection of human health and the environment in the European Community More particularly certain materials and components of waste electrical and electronic equipment needs selective treatment as their injudicious handling or disposing of on or into land water or air would represent a major threat to the environment and human health In order to facilitate collection and treatment separated from normal domestic waste electrical and electronic equipment is marked with the following logo Do not mix with normal domestic waste Please use the subjoined return or collection system dedicated to electrical and electronic waste Ww PS Equipment produced after August 13 Not only are you by law not allowed to dispose of the waste equipment via other wa
11. for all new setups These settings then apply to Load Default Address position Options are Top Middle Bottom Will apply to the hopper with the address carrying document Note the address can also be adjusted in Document Inserter Settings see page 17 Whichever was adjusted last will take precedence Feed Orientation Options are Face up Face down Not important Document Orientation Options are Head first Feet first Not important Fold Type Select from a preset list or Custom Fold Lengths Allows adjustment of the fold panels note that fold plate lengths will adjust accordingly Caution inappropriate length settings could result in operating problems Folded Length mm Allows adjustment if the actual folded length differs from the longest panel in Fold Lengths above Address adjust Adjust the address position if it is too far up or down in the envelope window ve moves the address further up the window Max Fold forms Sets the maximum number that can be grouped in the accumulator for folding together Groups larger than this will be split each section containing no more than Max Fold 5 9 6 Setting the output options CE This option is only available if a conveyor is fitted CE Select Save as Default to make this the default for all new setups Envelope batching Ensure that the Output tab in the configuration screen is selected This section allows you to
12. is properly set up see Setting up the Machine on page 46 Note A configuration can be associated with as many jobs as you wish 44 7 DAILY POST HANDFEED Daily post allows a group of forms to be hand fed folded and inserted Up to 8 forms of 80gsm 20lbs bond may be fed and they may be stapled or not as required see also Specifications on page 8 for stapling restrictions To use daily post the document must be created as Form Type Handfeed in the Documents screen see page 25 part view shown below Note that other sheets and inserts can also be collated with the hand fed daily post if required up to the limits shown in Specifications Document name a4 TI Icon 2 Form type Handfeed D Width mm 240 wW Depth mm 297 DI Paper Weight gsm 80 z Omr nam Computed Vv ahel narr To run daily post load feed hoppers as required if you have selected additional folded sheets or inserts see Loading Paper Hoppers on page 46 Select the job on the Run screen and press the Run button Insert the daily post documents into the handfeed tray on the tower folder or feeder folder as shown below the forms will then automatically be fed and the machine will await further documents Load the daily post with print side facing rearwards and top of form downwards Note Tower folder is shown feeder folder is different design but same principle
13. ne Vining serser Unit Fine Tuning Module 8 3p3h Folder Config Fine Tuning DEFAULTS tien a Ps eee y Hardware Fine Tuning y Document Fine Tuning Click on the feeder or folder on the machine graphic to display the fine tuning screen Feeder of any type No fine tuning of the unit part of the feeder is available Tower Adjust the address position if it is appearing too far up or down in the envelope window ve moves the address further up the window Note the address can also be adjusted in Module Settings in the Configuration screen see page 34 Whichever was adjusted last will take precedence Important All fine adjustments apply only to the current job and will not affect any other jobs Fine JONS Sera Unit Fine Tuning Module 2 Hopper 1 Config Fine Tuning DEFAULTS etomiman an mmevaa mm ase o o o Seomsertotin OOOO O oa O O e E Document Fine Tuning DL Card 99mm Hopper Fine Tuning Feeder and feeder folder or tower folder From here you can adjust hopper settings Click on the appropriate hopper and on Document Fine Tuning to display further information You can select 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
14. set up batching on the output conveyor where fitted Note This screen will only be available to personnel with Supervisor access Configuration DEFAULTS Barcodes Label Envelopes count 200 Control Mode Auto restart o rote Sm cs Posted 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 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 conveyor 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 disturbing 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 35 5 9 7 Setting Ensure that the Postage tab in the configuration screen is selected the post
15. setups Note OMR or Barcode reading are optional features X Y Lx Ly Specify the X and Y dimensions to the centre of the marks or label as indicated in the graphic Specify the length of the marks or label for vertical Ly or horizontal Lx reading Document I D Optional Feature 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 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 address is not stated as this will be determined by the printed address matching the lateral position of the envelope window If it is not the address document select 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 Notes 1 26 Minimum document width in the pack including inserts must be no smaller than the maximum document width by more than the following M
16. table 4 for Barcode Daily Post table 5 is not an option for TE this fold type 7 2 SHORT 3 SHORT 7 lp See following page for tables A 2 5 3 For chosen table use row A from step 1 This indicates oni oes r A orientation feed sequence and read head position where Va applicable YI 1 Note that for Daily Post only a ee configurations in table 1 column Willd LLM A err fob mu Fold generation requires Wilda f Foldplate 1 set to 1 3rd paper 7 length Foldplate 3 set to 1 3rd a a aper length g p p 3 p 1 LONG 3 SHORT ao EEL be Lo FA Vp a Preferred fold configurations are indicated bold and give correct address orientation in window of standard envelopes Van STANDARD C AND Z FOLD CONFIGURATIONS OFFSET V FOLD CONFIGURATIONS Shaded areas denote folds that give incorrect address orientation in window of standard envelope Reverse printing and or non standard window envelopes may permit use Note For some complex jobs not all paper trays may be loaded in the same way 57 58 Table 2 FEED TRAY LOADING WHEN ACCUMULATION TRAY IS NOT IN USE FORM ORIENTATION FEED ON FEED TRAY SEQUENCE BOTTOM TOP A lt 1 3dIS daddn LNIdd gt N TOP BOTTOM w PRINT UNDER SIDE N l gt BOTTOM TOP 30IS Y30NN 1NI d TOP BOTTOM i PRINT UPPER SIDE Ta
17. than 6 stations use the scroll arrows to move sideways Module U2 Haad Fuppar J7 raad sewdard Hgyyar Env Please select item from list 10 105mm 102 DL Plus 114mm 103 Select the required DL PlusPlus 121mm 104 envelope and click Ok 9 105 C5 6 114X229 106 c 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 19 29 5 9 2 Setting Click on the bottom section of the Inserter showing the unit icon and the inserter the following dialog box appears options for the Inserter unit c Select Save as Default to make this the default for all new setups These settings then apply to Load Default Seal Mode Deskew Item ID 30 Me Of Haad rlopper 1i raad standard hopper A Head standard hopper m 1 PlusPtus 121mm Please select and modify settings Seal Mode ee Options are Off Always Unseal OMR Select Off Flap Open if Off is selected flap is closed without sealing The setting of the amount of envelope deskew required Note a higher level will slow the machine more If available for setting must be set to Item ID 1 5 9 3 Setting Click the upper icon on one of the numbered units showing the the document document icon This displays the list of available documents to select options for the see page 25 for creating documents If the list is long a Find
18. that there is an intermediate setting between each marked position allowing finer adjustment Lower the side Slide positions cover and move A 0 to 0 75mm the slide to suit B 0 75 to 1 5mm the thickness of C 1 5 to 2 5mm the insert D 2 5 to 4 0mm A C only on Tower Feeder C Most jobs will use position A If you use the wrong setting an error will appear on the control panel 8 4 Using the accumulator If the machine is fitted with an accumulator this can be used for grouping forms prior to folding or for OMR Barcode grouping for subsequent removal by hand It can also be used to hold diverted forms for subsequent hand removal With an optional diverter tray fitted diverted forms can be fed into this instead The accumulator is located behind the tower folder Prior to use the side guides and diverter must first be set to suit the width and length of the paper as shown below Raise the accumulator channel to remove grouped Slacken the lock or diverted forms where screw underneath and applicable adjust the diverter stop to suit the length of the paper Slacken the lock screw and adjust the side guides to give 1 2mm clearance across the paper 48 8 5 Operator settable separator Optional The standard separator on the tower folder is spring loaded and operates with a preset gap for 80gsm 20lbs bond paper Under certain circumstances eg extra thick material it may be nece
19. the gap between them Feeders TRACK FEED Y lt 4 DD UPPER HP UPPER y a DESKEW Sey Va DD LOWER YA TRACK FEED HP LOWER COLLATE ENTRY ON POSTS DESKEW 2 ENVELOPE INSERT ENVELOPE WIDTH Lower the feeder side cover and raise the top cover Swing the green latch upwards to raise the roller platten Note station 1 feeder is shown others are similar 53 Double 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 HOPPER LOADED A DD LOWER fee gt DESKEW LOWER DD UPPER V o S 9 DESKEW UPPER HP LOWER g ad k HP UPPE Closer area Open the closer cover below the envelope hopper and direct the jet of air onto the sensors indicated by arrows in the following view For the sensor pairs liberally spray the air jet in the gap between them SEAL SN CLOSER OUTPUT 54 Tower Unit There are sensors in three locatio
20. 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 by 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 separator gap is correctly set see page 44 For the envelope hopper if jams occur frequently contact the Service Department Double 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 carrier 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 cover 2 Use the green knob on the feed 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 tower feeder to wind the crashed document into the cavity ahead it can then be easily removed 50 Tower Unit Open the side cover and operate the
21. 5 12 The Statistics SCrE N 0 ccc cece cece ee eee eee eee eee eee eee teeta eee eeed 40 52s I FilCET sdogana aaao dededentig a DE a aS 40 5 12 2 View SUMMATry ssssssssssssssssssrrrrsrerrrssrrnrrsrrnrrnereranrerrens 41 5 12 3 Current amp Previous SESSIONS ccc cc eeece eee e sees eeueeueuueeeeees 41 10 Di 2 4 Data LOGS inisiua n aar a a A tak A aar O AASE A 42 5 12 5 Open ATChiVe pikinio epi eee eee edie A a ve 43 Running The J OD cccccsceneeeeeeeeeeeeeeeeeeeseeeeaeeeeaeeeeeeeeeeauaeeoueeeananens 44 Daily Post Handfeed ccccccescssesseeeeeceeceeneeneeseeeeeeseeaeeaeeaeeasensons 45 Setting Up The Machine cccccseeeeeeeeeeeeeeeeeeeeeueeeeuaeeouaeeeuseeoneans 46 8 1 Loading the paper hoppers Insert Feeder Single tower OMR BahGOCG acces dicen A tanh vatswie a eaeAee on Fa erate dian ele ona E 46 8 2 Loading the envelope hopper 0 cece cece eee eee ee eee eae tate ened 47 8 3 Setting the Separator Qap cece cece eee eee tenet ee eae ea eee ened 48 8 4 Using the accumulator 6 Lecce eee eee eee teeta eae ee ened 48 8 5 Operator settable separator Optional ccceceeeeeeeeeeeeenes 49 Operator Maintenance cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeuseeausseeuseeansans 50 9 1 Clearing paper CraSheS ccccc cece eect teeta eee eee ea ene ened 50 9 2 Cleaning rollers ANd Sensors ccece cece eee eee eee ee teeta e reren rnn 52 9 3 Maintaining the wetting
22. FineTuningDocStandard FineTuningDocAll FAET From this screen you can edit the user that was selected in the list box see page 20 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 r les 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 box when the Users screen is saved and exited Check the boxes as required to set the r les access levels that are to be allocated the user To provide access to all r les select Superuser For further explanation of the r les contact 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 39 5 10 The Statistics screen sucos Hiii N a Engineering ba Sea Description of Button Functions Touch the OMR Code button to view all current OMR settings Touch the alee ees Comat Sonion Pens si Gers fan Dostinitea Touch the Prev Sansiene 51m0 Sanus L
23. 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 The machine is now ready to use Barcode reading and the setup you have created can be be selected for use in the Document screen 24 5 7 The Documents screen al Document One 3rd Letter folded Please edit avalaible and accessible settings if neccessary Document name Icon it One 3rd Letter folded Form type Width mm Depth mm Paper Weight gsm X Pre Folded Leaves Omr name 16 OMR SAMPLE TEMPLATE Label name FOG SAMPLE TEMPLATE AE elsave 96 ex From this screen you can edit the Form Insert setup that was selected in the list box see page 20 or click on New if creating a new setup The setup name and all form or insert 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 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 A4 will be used instead Icon Select the icon from a preset list this icon that will then appear in the graphic on the Configuration screen
24. MANON D pe OMR Codes Barcodes Label Envelopes Documents Jobs Engineering z B Admin OMR Code Barcodes Labels Documents Envelopes Configuration Job Users Statistics Engineering Admin Run Screen Description of Button Functions Touch the OMR button to view all current OMR settings Touch the Barcode button to view all current barcode settings Touch the Envelopes button to view all current envelope settings Touch the Documents button to view all current Document settings Touch the Configuration button to view all current configuration settings Touch the Job button to view all current job 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 Admin 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
25. TABLE OF CONTENTS 1 PMtrOCUCtION 22 ccc sce eee ee ee eee ee eee eeeeeeeeeeeeeeeeeeeeeeeeseaeeeeseeaeeseaeeseeeeenaees 3 Teh PIGEOQFAMS tcxeipoceti dk sede eee useec aes coursed Gav E EE 3 1 2 Notes on the Use of this Handbook cc cece cee cece eee eee tees 4 Safety NOtess cccccceeeeceeeeeeeeeeeeeeeeaeuaeeeuaeeeuaeeauaeeauaeeaseauseeausseansgeans 4 2 1 General safety NOteS cece cece cence eee teeta teense neta ee eee eae 5 22 ENG OF Vitesse ict a e ae tithe AN Seats 6 TECHNICAL SPECIFICATION cccccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeesaees 8 3 1 Machine rating sheet ccc eect teeta terete teeta tena na eee 8 Machine Layout Guide ccccceecceeeeeeeeeeeeeeeeeeeeuaauaeeeueeeeuseeeuseeauanes 9 4 1 Description of Machine cece eect e eee teeta eee aeee 9 4 2 Parts identification arae ete ieee ea ene a va be aes 10 Operating I NStrUuCtiONS cccceceeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeuseeeueeeoueeeans 11 5 1 What s in this DOCUMENL cece cece cece eee eee eee tae e een eed 11 5 2 Starting the Operating Program ccceee eee ee eects eee teeta ened 12 5 3 The Run screen explained ce ccece cece eee eee eee eee tate a eee ea eed 13 5 3 1 To change the USEP ccc ce cece cece e eee e teeta ea eenenes 14 5 3 2 To change the J OD ccc cece eee eee eee ee eee eae eae ee teens 14 5 3 3 To adjust the Envelope I nserter settings 15 5
26. age This section allows you to define weight groups for setting different options 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 DEFAULTS Miscellaneous 0 00 to 0 00 SOE Postage 0 00 to 0 00 NEE Postage USE Postage O Users an 0 00 to 0 00 XA Postage c Select Save as Default to make Engineering this the default for all new E aamin postage setups lire Wea Setting There are four weight groups each one defining a range with a lower and the upper weight and a postage rate to be set for that range The upper weight 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 group the four groups thres sana holds 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 Setting To set the postage rate for Group 1 click the Postage button and enter the the rate for that group Press Enter postage rates Repeat the above steps for the remaining groups if required Note The weight of the filled envelope is determined by the weight of ea
27. agt oomrate _ End Dale Endina daang Last dation Tivo 14 3 Dee Hide event data ty Touch the Touch the a FeedoroupS cetlAB Corda dnon Charge 5 Touch the FeecinousSaetlAD intemal Machne Stzpced I Wetter tark kw o ms 343 FeediroupScebloB nema Contguanon Change J 9 w 5 FaaciropSoulal intemal Machine Stopped a55 Wati tark lowe o 2 5 FeecGroupsceblaB tens Contgsanon Change 9 m 5 Touch the FuscircupSenlall intemal Machine Stopped GD Mohs Trt weeponding o o 5 FeediroupSreiiaB imema Buton Piers 2 Top Cover Open o w 5 Faninapso lin irtena Rumun Press 2 Top Cover Open o a 5 D Touch the FoectiroupSeetlAB emal Jeb Endes o mw s FomiGragScm lik irtena Machine Stoperd Ea Enveipe Seuestot Asna bier md pui 5 B fF medGroupScetian temal Machine Stopped mo Crweinpe Separator Area blocked J w 5 asana 111733 FammcticcngsSie lA irtena Mache Steg I5 Laer at ekoa Sapes fosa 0 mw s Touch thej onsems 11 17 39 FaectrousScetiA mtema Stopped by Operator w s 22s 1117 28 FarGnap ertl irtena Machine Stated 6 a 5 Jomo 11 17 27 FoediecunSicehlAB veal Baron Pets 1 Covert ogen o m s5 Touch the _J0C 06 2008 111613 FaetixagSin6lAB internal Mahre Stopes 451 Jam of kamtin Wetter ma m s5 02 05 2000 11 161 FeedioupbcebiAD intemal Stopped by Opsir O o xw s RASS 111603 Forde SerklaBy irtena Macte Started 0 o 1 5 02 05 2000 NIL FrecGeoupSaetiAll Internal Job Started o o m5 ARVO 11 16m FondiirougSerklaby i
28. at a distance of 1 meter from the nearest cover and a height of 1 6 metres from the ground The use for this machine is for collating folding and inserting documents into an envelope The weight of this machine is 290 kgs unpackaged 400 kgs packaged with accessories Based on a configuration 3 x Feeders and 3 Plate Folder Lifting or handling must only be carried out by competent persons using appropriate means 4 MACHINE LAYOUT GUI DE 4 1 Description of machine The function of the machine is to feed forms from a number of hoppers fold them in either C Z V or double forward fold and insert them into an envelope which is then sealed and ejected Further form s may optionally be collated with the first form either by folding together or collating on the track Inserts cards cheques etc may also be collated on the track before inserting The machine is OMR Barcode compatible allowing a group of forms to be collated in the accumulator prior to folding Forms may be inserted without sealing the envelope for subsequent hand insertion of card gift etc Multiple insertions may also be used ie a preset number of forms or combination of forms are separately inserted into the collation pocket in the inserter head 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 order
29. ated by untrained personnel The same applies to use that is inappropriate and not in keeping with its intended purpose In not adhering to this handbook there is the danger of an electrical shock injuries from the intake at the rotating rollers damage to the machine 2 1 General safety notes Caution Please read these notes with care Save these instructions for later use All notes and warnings found on the machine are to be followed Installing the machine Electrical danger Operating safety Cleaning the machine Cleaning sensors Important The machine must be installed only by an Authorised Service Engineer A safe level position is necessary when installing the machine with sufficient space all round to operate it The machine is to be protected from moisture If moving the machine ensure that the castor brakes are off and push on the stand not the machine Ensure there is at least 1 metre of free space between the operator side of the machine and a wall or barrier To provide access to the mains switch the opposite side of the machine must be at least 150mm from a wall or barrier Do not place surrounding furniture or other objects where your path may be obstructed The machine may only be connected to a voltage of 230V 50Hz or 115V 60 Hz depending upon model The mains plug may only be connected with a socket having an installed protective contact The protective effect will be comprom
30. ays OMR or Barcode Select the latter only available if unit is OMR Barcode enabled See OMR Barcode User s Manual for defining barcode setups Note OMR or Barcode reading are optional features Fold Mode Tower folder only Options are Singly Together Via accumulator the latter is only available if the unit has an accumulator 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 Reader Head ID Only available if Mark reading is On Options are Reader Head 1 Reader Head 2 Both readers Only available if two read heads are fitted 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 machine more 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 Default Separator Position Only available on feede
31. ble 4 FEED TRAY LOADING WHEN ACCUMULATION TRAY IS USED FORM ORIENTATION BCR READ ON FEED TRAY HEAD POSITION BOTTOM A BOTTOM FEED SEQUENCE Table 3 FEED TRAY LOADING WHEN ACCUMULATION TRAY IS USED FORM ORIENTATION OMR READ FEED ON FEED TRAY HEAD POSITION SEQUENCE TOP BOTTOM A lt BOTTOM Z A PRINT UNDER SIDE BOTTOM TOP TOP AS Z wo aals a3ddn LNIdd TOP BOTTOM PRINT UPPER SIDE BOTTOM TOP 30IS AJ0NN INI d Table 5 DAILY POST HANDFEED TRAY LOADING FORM ORIENTATION ON FEED TRAY BOTTOM
32. ch inserted document and the envelope These are set in the Document and Envelope options in the Setup screen see pages 25 amp 27 36 5 9 8 Setting the miscellaneous options Setting the datalog unit Address Carrier Confirm Calibration 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 DEFAULTS Please edit avalaible and accessible settings if neccessary Units Output Postage Metering E OMR Codes Miscellaneous options Con oie L i J hain dacilesging unii ea EER Main datalogging unit Prime Unit Please select tem from list Address carrier Module 8 Hopper 1 e a Confirm Calibration No r 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 the prime unit See page 42 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 32 Whichever is set the later takes precedence Select No if you wish the machine to continue running after a calibration cycle is performed by default machine will stop and await confir
33. ed these modules are briefly described below a Inserter head Collates all documents in a pocket before insertion feeds the envelope 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 Feeder Folder Mounts on the track either in conjunction with a tower folder see below or as the last station Fitted with one feed hopper and folds the same size stationery as the tower folder but uses a 2 plate folding mechanism An OMR Barcode version with one feed tray is also available c Tower Folder Mounts in the last station position and fitted with either one or three trays depending upon option Includes a 3 plate folding mechanism handfeed tray and an optional accumulator and or single divert bin The machine 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 The machine is OMR and Barcode enabled capable of reading a variety of different barcode symbologies Other symbo
34. envelopes 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 5 9 The Configuration screen Configuration DEFAULTS iccessible settings if neccessai Output Postage Metering Miscellaneous DEFAULTS 3 4 2h Feeder 2pth Folder 3pth Folder Ee DL Card 99mm ET DL Card 99mm Hopper 1 Hopper 1 Hopper 1 Hopper 1 er 2 Hopper 1 Hopper 2 Hopper 1 i siacnavaan aloo 3G ea From this screen you edit configurations that were created in the List Box after clicking the Configuration button in the Setup screen see page 19 or click on New if creating a new configuration 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 38 You can rename a new configuration by clicking on 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 5 9 1 Click the upper icon on the Head part of the graphic showing the Configuring envelope icon This displays the list of available envelopes to allow the inserter you to select one see page 27 for creating Envelopes If the machine has more
35. etc Allows testing of various parts of the machine Only available to personnel with engineer access and described in detail in the machine Service Manual Allows administration of various machine functions Click on this to take you back to the Run Screen 19 5 4 2 The List Box Click on any of the buttons on Documents the Setup screen to display a Curenty selected E list box Shown left is the list Insert 160 113 PEA EET box for the Document and is r e teers Lies similar for all of the buttons wath rr 240 on the Setup screen The list Een A box shows all of the setups DL Card 99mm 103 Trewen aa that have been defined so far cpiaaencien Computed Yes Select any of the setups shown ome name None Label name None and this can then be edited Pre Folded Leaves 1 ee a retra copied or deleted by clicking on n Doc m the appropriate button at the One 3rd Letter folded 108 bottom of the box New setups Half Fold Letter 106 can also be created by clicking on the New button and the newly created item can then be ee ee edited as required Note that Jan_draft_ttr 111 each name is allocated an ID number by the software this being 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
36. inimum document width Maximum document width 2 58mm eg if maximum document 210mm minimum document width 210 2 58 163mm minimum 5 6 The Envelopes screen Envelope name a et Envelope Untitled Envelope1 Untitled Envelope1 Width mm Depth mm Paper Weight gsm Flap mm Wetting rate i Save As Default Label name True Weight g From this screen you can edit the Envelope setup that was selected in the list box see page 20 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 from a preset list this icon that will then appear in the graphic on the Configuration screen see page 29 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 C
37. ised by the use of an extension line without a protective grounding conductor All interruptions of the protective grounding conductor within or outside of the machine are prohibited The device is double pole fused When fuse failure occurs electrical machine parts can still carry voltage When making the connection to the mains power be aware of the connection values on the nameplate Inspect the voltage setting on the device s power input module Run the supply lines in such a way that no one may trip over them Do not place any objects upon the supply line When the machine is not in use over a long period of time it should be disconnected from the power supply In this way damage would be prevented in the event of excess voltage Protect the device from moisture When moisture enters the machine there is the danger of electrical shock Never open the machine except the top cover For reasons of electrical safety the machine may only be opened by authorized Service Agents Never reach into the machine when it is running This could only occur if a safety interlock were to fail The danger of injuries exists through pulling in and crushing on the rotating rollers In addition keep long hair and parts of loose clothing far from the machine in operation If a safety interlock fails your Service Agent must be contacted immediately In order to prevent damage to the machine only factory authorized accessory parts should be used Pri
38. l Data logging characters If data logging is being used click on and enter the start character position and number of characters See also page 38 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 Enter the start character position and number of characters Click on and enter the start position and character length of each function either by typing it in the Enter Value box or by using the on screen keypad Number 1 is the first mark from the leading edge 0 zero means that character is not used Note a minimum of 4 characters must be used See also 100 140 Barcode Specifications Form sequence within a J ob This is used to ensure that forms are processed 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
39. le for Job A job Event_Another DCO_040908 iz Event_Another DCO_050908 Date Time Event Dest Doce Event Data Event_Another DCO_080908 10 07 2003 12 10 06 Button Pressed RUN 1007 008 12 1008 K i i JabRun Started Event Another DCO_270808 10072008 12 10 09 C 6 Machine Started Event Another DCO 280808 1007 008 12 10 12 A A 4 Machina Stopped 10 07 2008 12 10 14 0 A Machine Started Event_FixedGroupSize JAB 07 1007 2009 12 10 15 2 f null Event_FixedGroupSize JAB _08 k pae i y null i Event _FixedGroupSize JAB _10 1007 7008 121017 D i BIDAAAARARI B 7 A 1007 2003 12 10 18 2 0 null Event_FixedGroupSize JAB _1 2008 121018 D null Event_FixedGroupSize JAB _15 Machine Started null null nuli 10 07 2008 12 11 27 b i null 1007 2008 121128 D i ruil null null Ok Points to note 1 Data is logged using only the barcode characters selected in the Barcode screen see OMR Barcode Users Manual for defining barcode setups This can be all of the characters Note OMR Barcode readings are optional features 2 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 document Data Log Specification 5 10 5 Open Archive Select Open Archive on the Statistics Diagnostics screen to displa
40. logies can be accommodated at special request A daily post function can be used on the handfeed tray built into a tower folder as standard and is an otional feature on a feeder folder This allows groups of documents stapled or loose to be hand fed they will then be folded and inserted into an envelope If other hoppers are loaded further forms can be collated An optional daily post function is also available on the feeder folder No manual setting of the fold plates or envelope closer is required these being adjusted automatically according to the settings in the selected program An optional output conveyor can be specified to replace the standard receiving tray This is available in two lengths 4 2 Parts identification Daily post tray PC control panel Tower feeder Tower folder Standard feeder see below Insert collate area Envelope hopper Note Station 1 is the first feed unit after the insert collate area Filled envelope tray Storage cupboards PC under insert head Feed trays either 3 or 1 Tower Folder Accumulator optional Forms diverter optional Accumulator sideguide 10 5 OPERATING INSTRUCTIONS 5 1 What s in this Document On line Help These Operating Instructions guide you through the stages of using the machine The machine is entirely software controlled with all operator functions being performed on the touch sensitive control screen Differe
41. m residues as required 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 If 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 underneath it and pulling out the bung to drain into a suitable receptacle 56 10 DOCUMENT ORIENTATION TABLES Paper orientation on the feed hoppers will depend on fold type accumulation tray OMR Barcode and feed sequence The example below shows how to reference the required orientation from the tables Note that for most applications the LEDs on the rear edge of the 3 plate folder will indicate the required orientation Tab Example a ADDRESS FOLD P e eH 2 Fold Chosen is top address C 7 aA TTT ADDRESS fold i i pa VF 1 Select configuration from table D007 1 Note column A unshaded Pm pe 2 OMR or Barcode If NO use a x table 2 If YES use table 3 for Z I i J Uy OMR
42. mation 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 37 5 8 The Job screen Please edit avalaible and accessible settings if neccessary Job DEFAULTS Job name Configuration Late divert Current settings Module 0 Hopper 1 DL PlusPlus 121mm Seal Mode Always DEFAULTS Module 1 Hopper 1 DL Card 99mm Feed Control Mode Feed always Module 2 Hopper 1 DL Card 99mm DEFAULTS Feed Control Mode Feed always Module 3 Hopper 1 DL Card 99mm Feed Control Mode Feed always Module 3 Hopper 2 DL Card 99mm Feed Control Mode Feed always Module 4 Hopper 1 A4 Feed Control Mode Feed always Module 5 Hopper 1 A4 Feed Control Mode Feed always Module 5 Hopper 2 A4 Feed Control Mode Off Module 6 Hopper 1 A4 Feed Control Mode Feed always Module 6 Hopper 2 A4 Feed Control Mode Off Module 7 Hopper 1 A4 Feed Control Mode Feed always Module 7 Hopper 2 A4 Feed Control Mode Feed always Module 7 Hopper 3 A4 9G Eri From this screen you can edit the job that was selected in the list box see page 20 or click on New if creating a new job The job name can be changed and or a different configuration associated with it Editing the job name Selecting a configuration Logging OCR data Late divert Checking 38 Click on Job Na
43. me 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 29 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 ocr_ lt Jobname gt _ lt Date gt txt ocr will vary for different data types Set this to Yes to use customer 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 All 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 5 9 The Users screen Please edit avalaible and accessible settings if neccessary User Gemima Roles User name Password C2 Senior Operator Cemina Operator Supervisor Engineer Admin _ Special Superuser RunScreenShow RunScreenStandard RunScreenAll FineTuningDocShow _
44. nce within a Job Symbology Default Form Sequence within a Group Grouping End of Group Matching Good decode reads 3 Security check On Data log enabled off Divert oversize group Ho Divert blank sheet No Data logging characters Start pos 1 Security Customer ID characters Form Sequence within a Job 0 Incrementing Start pos 0 Form Sequence within a Group Incrementing a Save x Exit From this screen you can edit the barcode or other ID label setup selected in the list box see 1 2 or click on New if creating a new setup The setup name and all label settings can be changed as required Editing the setup name Editing the settings for non BCS characters Click on Barcode 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 Barcode list box when the Barcode screen is saved and exited The buttons below Name relate to label settings and other non BCS character functions These are briefly described below Definition mode Only As printed is available Number of characters in label Up to max 25 for BCS system Label machine control The type of control system the machine will use to decode the label Options are Standard BCS default Neopost 3 Customer ID 3 of 9 Numeric 2 of 5 Last page custom 1 Custom control 2 For all except Standard BCS the Tech
45. ndicator 2 See the following page for setting the curled forms stop Tower Folder curled forms stop Documents that are slightly curled may not feed properly as the leading edge may become snagged at the infeed To help overcome this each hopper tray is fitted with a 2 position stop that can be raised or lowered 1 Withdraw the hopper and pull both of the spring loaded knobs outwards 2 For flat forms or forms curling upwards select the upper default position 3 For forms curling downwards select the lower position Pull both knobs Raise or lower moveable out together stop 4 Ensure both knobs are properly located before replacing the tray 8 2 Loading the envelope hopper Pull the weighted roller back and load the envelopes ensuring they are fully down flaps must be facing forwards Release the weighted roller so that it tips the envelopes into the pickup roller An alternative heavier roller is also available part no C3656A which can improve feeding of thick booklets This must be fitted by a Service Engineer Slacken the lock lever and adjust the side guides to give 1 2mm clearance across the width of the envelopes Tighten the lock lever 47 8 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
46. ng program you will be presented the Operating with the Run Screen shown below and described in detail on the Program following page 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 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 ymos a 00ga User Logus Russell please enter your Password Note New operators and passwords can be only be entered or edited by authorised personnel with Supervisor access This is detailed in section 5 11 The Users Screen on page 39 12 5 3 The Run screen explained From this screen you run and stop the machine and control the speed It is also possible to change the selected user change the selected job and enter Edit Configuration authorised personnel only Current time Machine Exit to setup and date Select user graphic Select job screen Exit software D 16110 2008 14 29 45 Internal DEFAULTS a EE R Status Reset count Autoend Run button Output rate Speed control Double Process one Stop button indicator and indica
47. ng 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 43 the Previous button will restore the events that were displayed prior to its opening 41 5 10 4 Data Logs 42 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 and select the required log as shown below Select from list Events Data Logs Docs Output Data Logs Docs Error Data Logs Docs OCR Data Loo ETN Event_A job DCO _100708 Event_A job DCO _110708 Event_A job DCO _140708 Event_A job DCO _220808 Event_Another DCO_020908 Postages Data Logs All Other Data Logs All Data Logs Mi Event_A Job DCO 100708 1x4 Event_Another DCO_030908 Event Data Log fi
48. nical Support department must be consulted Symbology The code type of the label being read Options are Default Code 2 of 5 Code 3 of 9 Code 128 2D Datamatrix Grouping Select whether the group mark is End of group First of group or 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 23 Editing the settings for BCS characters Security 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 not used for MS3 reader Data log enabled If selected a record of the movements of each group will be retained in a log file 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 the 100 140 Operator Manual 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 labe
49. ns Open the side cover and swing the green latch upwards to raise the roller platten Clean both halves as shown HOLD POINT 4 UPPE HOLD POINT 4 LOWER 9 o With the side cover open swing the green latch forwards to open the daily post hopper Clean both halves as shown O 5 2 T O lt i PE Hinge the top cover forwards and liberally spray the air jet in the gap indicated to ensure both halves are cleaned DOUBI DOCUMENT D DESKEW Ce YX J a LOADE 55 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 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 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 gu
50. nt 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 indicated The Operating Steps The functions described in this document are e The Run Screen from which you control the running of the machine e The Setup Screen where you select items that need setting up e The OMR Code Screen to allow you to define OMR marks for up to four reader heads e The Bar Code Screen to allow you to define Barcode characters e The Documents Screen for defining the forms or inserts to be used e The Envelopes Screen for defining the envelope to be used e The Configuration Screen where you set up the envelope inserter and feeder units to use the selected stationery e The Job Screen to allow you to define a job name and associate it with a machine configuration e The User Screen for creating operator names and allocating a password and access permissions e The Statistics Screen for viewing production data e 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 5 2 Starting When you first start the operati
51. omputed 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 above will not be active 27 Editing the True Weight This shows the weight of the envelope in the units shown and settings contd 28 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 36 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 greatest 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 OMR Barcode User s Manual for defining barcode setups Note that the label can be printed either on the document for reading through the window or on the envelope Note OMR or Barcode reading are optional features Click the Save as Default button if you wish this to be the setup that new
52. or to cleaning the exterior of the machine it should be disconnected from the power supply When cleaning the machine do not use liquid or spray cleaners but only a cloth dampened with water When cleaning sensors use only non flammable airdusters eg part number E0070A Other types may use flammable propellants which could result in fire or explosion Allow In the following cases the mains plug must be unplugged and the device machine to left for the authorized Service Agents be checked When the mains cable or plug is worn or damaged by the When water or other liquid has entered the device Service When the device does not function properly in spite of Agent following the instructions provided When the device has fallen down or the housing is damaged e When there are noticeable differences in the normal operation of the machine Spare Parts When repair work is carried out only original spare parts or spare parts corresponding to the original parts may be used Repairs Do not disassemble the machine any further than is described in this handbook Other than the top cover the opening of the machine by unauthorized personnel is not permitted Repairs may only be carried out by an authorized Service Agent Modification is not permitted For safety reasons your own reworking and modifications are not permitted Please contact your Service Agent for all questions relating to service and repair In this way you
53. r 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 or a warning will be flagged with the first insertion cycle only Note this setting is duplicated in the Fine Tuning screen see page 18 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 33 5 9 5 Setting If the unit is a tower folder or feeder folder click on the uppermost the module section of the graphic above the document icon and the following options fora dialog box appears Folder Ee Select Save as Maximum Fold Forms 34 m Moduls 72 Judi Foldar 3p3h Folder Please select and modify settings Fold Type Feed orientation Document orientation Fold Plate Lengths mm Folded Length mm Address adjust mm Default to make this the default
54. r way round the paper is fed and whichever way up it is loaded in the hopper If As fed it must be in the direction and orientation as specified in the unit settings in Configuration this mostly applies to legacy jobs 21 Also set the Pitch Gate position from Top of Form Leading amp Trailing margins allowable tolerance for printed mark set to drift and still be read Divert oversize group Y N Divert blank sheet Y N and Address on every page Y N Now select 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 using a SI CK read head the machine must first be calibrated by an engineer This is not necessary with an MS3 reader Note also that a SICK read head is available only on a Mark Reading Feeder 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 The machine is now ready to use OMR reading and the setup you have created can be be selected for use in the Document screen 22 5 6 The Barcode Label screen Please edit avalaible and accessible settings if neccessary Sen Wien Barcode Wk 44_2 Barcode name Wk 44 2 Character Function Start pos Length As printed Grouping Number of characters in label 14 Select Label machine control Standard BCS Control ee mee Form Seque
55. rirna Buton Press 1 Covens a pen Ls 1 oasa n1023 Foesiopseesan imema Job Endet 0 o w 5 AIR 11 0855 FredGonpSechlAB itema Mache Streed 451 Jam ot veto Welie Are o 1 02 05 2008 11 09 55 FaedirowSaelAl Iriemsi Stopped by Oper O o w 5 eoa 11 08 35 FeediroupSeehiAB intema Machine Stoned 0 wis Josa noS FanstincpSeuflAl vansi Mian Press 1 Cerapan o we 5 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 39 for details of archives Press Show event data if no data is displayed Your first action should be to filter out data relevant only to what you wish to know as decribed below 5 10 1 Filter 40 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 ai Select Records Filter 00 00 00 Yesterday End Time 00 00 00 All Dates dob Operator a End Date aavon o0 Clear Filter Detault 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 informa
56. see page 29 Form type Select the form type from a preset list 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 below Pre Folded Leaves If the insert consists of more than one leaf eg a Z folded flyer click the button and enter the number of leaves Thickness If the insert is a booklet or other thick material click the Computed 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 25 Editing the True Weight This shows the weight of the document or insert in the units settings shown and is linked to Thickness above To enter a known weight click contd 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 36 OMR Name Click this button if you are using OMR then click the Name button and select an OMR setup see page 20 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 OMR Barcode User s Manual for defining barcode
57. ssary to open the gap or in some cases to close it As standard this can only be carried out by a Service Engineer but with some stationery this may not provide a sufficiently sensitive adjustment The optional operator settable separator allows the operator to set the gap using a knurled knob on each of the hopper fitted 1 or 3 It can be specially useful when double feeding has been a problem with the standard separator as it allows fine tuning Where fitted the separator is accessed by opening the side cover of the tower folder the separator is behind an opening Set the separator gap to suit 80gsm 20Ibs bond paper or to a different setting as required This is most easily achieved by removing the top tray and for 3 tray machines the second tray also Lift out the infeed bridge with cork strips to prevent drag from the pre feeder Slide a sheet of the stationery into the separator gap and adjust the knurled knob until a moderate drag is felt on the paper as it is withdrawn rearwards Refit the infeed plate and trays Turn the adjusting knob to achieve the required setting see above Note separator is shown with black inner cover not fitted 49 9 OPERATOR MAINTENANCE 9 1 Clearing paper crashes 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 Insert head and feeder Raise
58. ste streams but we encourage you to actively contribute to the success of such collection and to the common good and better quality of life of present and future generations For more information on the correct disposal of this product please contact your local dealer 3 3 1 TECHNICAL SPECIFICATION Machine rating sheet CAUTION In order to ensure correct safety and operation this machine must only be installed and maintained by an authorized Service Engineer CAUTION Should any cover or safety interlock be damaged the machine must not be used until service repairs have been completed CAUTION This machine must be earthed The wire colours in the mains power cord are Green Yellow 230v Green 115v which must be connected to Earth Ground Blue 230v White 115v which must be connected to Neutral Brown 230v Black 115v which must be connected to Live Line CAUTION This machine is supplied with an unterminated mains cable for hard wiring or connection with a suitable 16A plug socket conforming to IEC 60309 CAUTION For continued protection against risk of fire replace with same type and rating of fuse The fuse rating type for this machine is T 6 3 A Amps 230Volts Part No 135 106 T 10 A Amps 115Volts Part No 135 110 Model Details Model Name 140 series Model Number 1430 Input Voltage 230 Volts 50 Hz 115 Volts 60 Hz Input current 3 5 Amps 7 Amps Sound Reading 75dBA 75dBA measured
59. te 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 Hopper Fine Tuning Suni 3 Sofas unit Fine Tuning Module 0 Hopper 1 2 From here you can adjust hopper settings Click on the inserter hopper then Document Fine Tuning to display further information You can 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 depth and flap depth if actual envelope varies from the settings shown Wanning if the same document is used on other jobs as well the same settings will be applied Important All fine adjustments apply only to the current job and will not affect any other jobs 16 5 3 4 To adjust Note Click on the Unit button in the top the Document left corner to toggle between fine tuning for Inserter unit shown here and hopper shown overleaf settings The settings available will vary between feeders and folders a Tuning sersan Fine Tuning Module 1 1h Feeder Config Fine Tuning DEFAULTS y Hardware Fine Tuning X Abort S dott cument Fine Tuning
60. the documents being run are substantially different from the calibration document such as abnormally dark with heavy printing c Separator Position feeder or tower feeder only 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 29 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 18 5 4 The Setup screen 5 4 1 The Setup screen explained p ios Versi ER 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 on the Run screen
61. tion as described on the following page 5 10 2 View Summary 5 10 3 Current amp Previous sessions Press the Summary button to view the filtered data Note that only valid events will be shown ie 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 1709 2008 13 STATISTICS SUMMARY 17 09 2008 i DusiTreckTest Documents Fed pm Module Filed Envelopes 19 09 2008 Tenors Docs Production Dutput DuolTrackTest Production Rate 19 09 2008 18 Ai Jeb Run Eom Misiones 19 09 2008 171072008 1455 10 Haed Envelopes pet Portage Groups 7 shed 17710 2008 14 56 34 ns Ejected Removed Postage 19 09 2008 18 5 A M 24 09 2008 E 00 01 16 Setting Downton 7 e S 24 09 2008 oon Operator Downtime x ji ow i 00 00 02 Emor Downhene lt 24 09 2008 4 Excess Dowetine aoe o 24 09 2008 16 10 2008 16 10 2008 16 10 2008 16 10 2008 16 10 2008 16 10 2008 16 10 2008 17 10 2008 17 10 2008 Tri i ele Lt sa s sjsjs s as s s sajsafsjs sjaja Stee ele 6 ele Slat j selesilestelesoy 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 pressi
62. tor document cycle 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 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 following page for details 5 3 1 To change the User 5 3 2 To change the J ob 14 lease select item from list Operator 101 lease select item from list DEFAULTS 101 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 19 Click on the Select J ob 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 19 5 3 3 To adjust the Envelope Inserter settings Unit Fine Tuning Fine Toning Sera Unit Fine Tuning Module 0 Head Hardware Fine Tuning Module 0 Head
63. two green latches to raise the roller platten and open the daily post hopper Also open the top cover to access the upper part of the feed hopper Carefully withdraw any jammed paper taking care not to tear it turn the green knobs to help wind jammed paper out of the rollers 51 9 2 Cleaning rollers and sensors Periodically all rollers feed wheels and sensors should be cleaned especially if a long run is envisaged Use only Rubber Roller 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 dampened with water Clean the full circumference of rubber rollers feed wheels and conveyors in the area of a Feeder folder 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
64. using a cloth dampened with Roller Restorer Fluid clean all the rollers both upper and lower Use the green knob to help rotate them Clean all 12 rollers To access tower folder rollers open the LH side covers and use the green latches to open the daily post hopper and paper path platten Also open the front cover using the black latch on the top edge Cleaning sensors When cleaning the rollers the sensors should also be cleaned by blowing away dust and debris 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 part no A0070A 52 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 of COLLATE POCKET ope COLLATE INPUT UPP COLLATE POCKET LOWER fe o COLLATE INPUT LOWER ae OO a For the sensor pairs liberally spray 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 position by a latch O HOPPER LOADED 4 the air jet in
65. y 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 machine at C Program Files Pfe Maximailer Plus Data Archives DB cg Monthly archives are shown see text below for archive format Select from list Daily Archives Faulty Archives Monthly Archives All Other Archives Jul_2008 Jun_2008 May_2008 Select from list Jo 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 format 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

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