100/140 OMR & barcode Mounting Instruction
Contents
1. ueese 22 4 5 Barcode reader diagnosis 140 serieS sssssssssssrerersrenenrnns 22 4 6 OMR reader calibration 100 series eene 22 4 7 Barcode reader calibration 100 series eese 23 4 8 Using Trace Tool 100 Sees yogwesieoeas ena ses o pts smpodaa pur dass vt aa iutadus 23 5 OMR and Barcode definition eere nnne nnn nnn 24 5 1 Entering the licence key e rese vakans veces paw uus Dco Ux VERE E FAN XN FREE 24 S OM GS CON oo rt ata a E nM PUEDE e ii ia n 25 5 93 Barcode defNIUON UT 26 K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting Page 1 of 28 FITTING AN OMR OR BARCODE 2D READER This appendix describes the installation of an OMR read head or barcode 2D reader for ma chines later upgraded to OMR or barcode 2D specification It also covers read head setup alignment and calibration so if it is required for example to move an OMR head position from LH to RH this document describes the procedure SECTION 1 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 Nevertheless2. Repeat calibration if OMR beam is flashing calibration failed Otherwise calibration has been successfull Press Ok to finish If no errors are displayed the head is now calibrated and need only be calibrated again if read errors occur or the unit fails to read at all A working reader will flicker on and off as the marks are slowly fed past the head Page 21 of 28 4 4 Barcode reader calibration 140 Se ries Calibration of the barcode reader requires nothing more than confimation that it is work ing Switch on the power and start the oper ating software then wind a piece of barcode marked paper under the reader From the Run screen select the hopper of the appropriate feeder to and press Reader On Fine Tuning seraan Unit Fine Tuning Module 8 Hopper 1 Config Fine Tuning DEFAULTS Feed Control Mode Feed always Doubles Detect Do mum no on X Abort Jf Do It When the marked paper is under the reader and being successfully read the reader will beep in confirmation Although the read ing angle is quite large the marks should be centrally placed under the reader difficult to see with bottom read This is best achieved by moving the reader over to one side out of range of the marks then back until the unit beeps Continue until it stops then move back approximately half that distance 4 5 Barcode reader diagnosis 140 Se ries The calib
3. nit 4 gt Head standard hopper Module 5 Hopper 1 Module 5 Hopper 2 Module 6 Hopper 1 Module 6 Hopper 2 Module 7 Hopper 2 Module 7 Hopper 3 Module 7 Hopper 4 Madula R Hanner 1 Module handfeed hopper Blank station al save YO Exit Fig 11 Select Module for the tower unit then select the type of reader for each rel evant channel number as shown in Fig 12 Ch 1 4 are for OMR reader Ch 9 amp 10 for barcode See Fig 26 for further explanation of channels DS 100 140 OMR amp Barcode Mounting EX Mode to Together via accumulator and set Reader Head ID to 1 or 2 u depending on which side of the hopper the reader is fitted Save and exit the configuration Note the document used in the hopper must have an OMR setup associated with it or Mark Reading will not be enabled See Fig 14 below Unit types and modifiers Unit equipments E 4 gt Head 60Hz supply Units R 1h Feeder vi Daily post Module 4 Hopper 1 1h MR Feeder On Line Module 5 2h Feeder Divert Module 5 Hopper 1 3h Feeder Accumulator Module 5 Hopper 2 2p1h Folder Second wetter Module 6 3p1h Folder Franker Module 6 Hopper 1 723p3h Folder Camera Module 6 Hopper 2 d DTI Module 7 Hopper1 Module 7 Hopper2 Module 7 Hopper 3 Fig 12 CH In Engineer mode select Di
4. F Mark 2 blank W P Mark 3 blank t Mark 4 blank AW P Mark 5 blank e P Mark 6 blank W P Mark 7 blank Sd gt Mark 8 blank sd P Done Make selections as required to define each mark as explained in OMR Specifications for 100 140 Series The points shown on the following page must be noted DS 100 140 OMR amp Barcode Mounting e Mark 1 is always the gate mark and can not be changed e Marks are defined in print order not feed order e Marks must be defined in specific fixed order For PFE OMR marks the order is as follows Gate default Group EOG FOG Parity Divert No seal Select item 2 10 Sequence in Job 1 5 Sequence in Group 1 4 Force fold Auto end For Neopost 2 track OMR marks see the order defined in Two track OMR Specification and Functionality for 100 140 Series When all marks are defined select Done Naming the job After editing the marks you move to the Save screen which allows you create a new name for a new definition or simply press x if editing an existing one you will be asked to save before exiting the edit mode NEW NAME To enter a new definition name use the Scroll Up Down buttons to select the first charac ter then press v This moves to the second character and so on up to the maximum 10 characters When finished press x to exit the screen Confirm your changes and your new definition is now saved
5. The types of licence available are e BCR Flex up to 9 e OMR Flex up to 9 e BCR Adv 1 only e OMR Adv 1 only e OMR T always applies e MPPC 1 only LICENCE gt Machine ID BN3G UMN 24 DAA b Enter Licence Key D Feature Set 0 4300 0133 5009 K4 0068 A Issue 5 June 2011 DS 100 140 OMR 8 Barcode Mounting Page 25 of 28 5 2 OMR Definition Creating an OMR definition allows the opera tor to select it for use in a job setup Up to 9 definitions can be created depending upon the option chosen at machine purchase The template for the definitions will have default name usually OMR 1 OMR 2 etc which can be renamed after defining To define the OMR setup enter Engineer mode This is carried out by selecting Super visor on the Main Menu then entering the PIN of 451 Scroll down to OMR definition and select one of the available templates either an unused one for creating a new defin tion or an existing one for editing ENGINEEH LI P Env Only Mode Set Default Supervisor PIN P View throughput LIIS P Sensor Cal Super gt CONFIGURE SYSTEM gt Licence Set up P OMR definition f1 Flex 1 BCR definition a AdvO V e You can now make required selections from the template see descriptions opposite EDIT OMH 1 Code Type 1 track gt Number of marks lt T l Gate mark Top Ea Pitch gt Parity Form seq start c
6. All OMR definitions created in Engineer mode will be available to the operator for selection when creating jobs that use OMR stationery K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting 5 3 Barcode Definition Creating a Barcode definiton allows the op erator to select it for use in a job setup Up to 9 definitions can be created depending upon the option chosen at machine purchase The template for the definitions will have default name usually BCS 1 BCS 2 etc which can be renamed after defining To define the Barcode setup enter Engineer mode This is carried out by selecting Super visor on the Main Menu then entering the PIN of 451 Scroll down to BCR definition and select one of the available templates ei ther an unused one for creating a new defin tion or an existing one for editing ENGINEEH Burn in Mode Env Only Mode i Set Default Supervisor PIN View throughput P Sensor Cal Super D CONFIGURE SYSTEM OMR definition gt ECR definition OMRIA F BCS 1 E You can now make required selections from the template BARCODE BCS 1 bmMachine control BCS je Symbology 3of8 P Characters in label 8 End of group T Form seq start count h ji Form seq count dir Increment Group seq start count a ji b Grouping gt Group seq count dirl
7. Gate 2 is middle tray ANALOGUE SENSORS 4 P Prefeedl P Deskewl P DDI P OMR Gatel D Prefeed 2 gt Deskew P DD2 OMR Gate Exit Engineer mode Now enter Edit mode for the relevant job and select Edit Item for stations K4 0068 A Issue 5 June 2011 1 2 on the tower unit set Mark Reading to OMR or barcode as required and tick Cascade if a reader is also fitted to the middle tray as shown in Fig 10 below SHEET ITEM 2 P Feed Mode Feed always gt Packlength Fold Type View Fold Settings b Feed orientation Fold mode Mark Reading b Cascade Fig 10 Use cable ties to secure added wires and cables away from any moving parts snag points or sharp edges Replace all covers unless station 2 cas cade OMR is also to be fitted in which case see section 2 6 The OMR barcode job is now ready to be run If OMR read problems are encoun tered use the OMR scope function in the Trace Tools debugging utility described in section 3 14 5 of the service manual 2 5 DS 140 Configuration 1 Please fill settings Enter Engineer mode from the setup screen and select Hardware Setup Se lect the Edit tab then the appropriate hopper of the mark reading unit s Set the number of readers for each hopper as required as shown in Fig 11 below Humber View Edit Unit types and modifiers Module 6 Module 7 Module 8 of modules
8. NMOHS SI Qv38 dOL HY Z JOHS YNO NUN JNiddS DO HOM AIG LONI ywo YMA0 G EO EY Jg Zak E LIM NOLVIS L MO NMOHS SV LI YWO j MAN AA e LJJ31 NIB L Av YWO gO SLEO EY FIONIS AVvAYITE YOS SIMVd JAYS JSN aak X 91 1L NIduo AIO v6osci NOU LAIMOS30Q ON dv EN No ANY JXTW M pu 7 Lc vZ8192 nc Jj SNOILdO NOILISOd 33Q0v34 YWO JO 1S 100 LR VSOQCZY AlaNasSv LOO ano Page 6 of 28 2 3 Fitting the OMR assembly to a tower unit top tray LL K4 0068 A Issue 5 June 2011 Remove the RH side cover and the tower access assy front amp top cover the tower access assy is the pivoting section at the top front of the tower Remove tower access assy this is not essential but is quick to do and greatly improves access The pivot bar is re tained with a screw at each end and a nylon strap On the RH side remove the jockey gears shown in Fig 2 This provides access to the end of the transport roller shaft and OMR plate scews Remove gears Remove the E clips T bearings and springs from both ends of the transport roller shaft and lift it out of the chassis In its place fit the OMR transport roller shaft A2844A supplied in the kit Assemble this with the nylon encoder mount P2150A in place of the TI bearing on the LH end Note that the stepped end of the shaft runs through this mount Assemble the encoder base plate to the nylon mount using 2 of
9. D Prefeed3 3 7 P gt Deskew3 9833 2 P gt DD3 335 4 7 P gt HP4 347 0 3 P D Track jh 0 7 P gt OMRI 077 1 0 F gt OMR3 204 1 4 P gt OMR4 065 1 0 P V b Select the required OMR head OMR1 2 etc and press v You will then be prompted to plaece a piece of white paper under the head on press v again After successful calibration a confimation will be displayed DONE ouccessfully Calibrated The OMR head need only be calibrated if it is changed or if the control board is changed or if read problems are occur ring K4 0068 A Issue 5 June 2011 DS 100 140 OMR 8 Barcode Mounting 4 3 OMR head calibration 140 Series mark reading feeder fitted with SICK read head only After alignment of the OMR head it must be calibrated To carry this out on a 140 Series with an OMR feeder fitted with a SICK read head enter the Run Screen Select the hop per of the appropriate feeder on the graphic to display Fine Tuning seras NENEENNCITCITUITONERNEENNN 7 Feed Control Mode Feed always Off On Doubles Detect Off Off On Deskew Low Select Calibrate reader Separator Position A 0 00 0 75mm Select Y Document Fine Tuning X Abort S Dott Press Calibrate reader and follow the on screen instructions Unos E Confirm AEN Position c ihlos a Mark Information Press Ok to c Move ios EI position bea Information Press Ok to
10. A3292A or A3296A TOWER TOP COVER PN B7645T pe cM NOT PART OF HORIZONTAL qur BN BARCODE ASSEMBLY A3 0375 BBH pos l ai J BARCODE SLIDE BAR C9676C BARCODE SCANNER MS 3 179 764 M4 x 8 POZI PAN HD T T SCREW ae A CAP HD SCREW E2701A Ld d Na A LASER CAUTION LABEL a HORIZONTAL BARCODE G3363A MEN SLIDE BRACKET Ss Br a R2958A TOWER ACCESS LATCH t f R2033F be uum NOT PART OF HORIZONTAL a BARCODE ASSEMBLY A3 0375 BBH G M4 x 8 POZI PAN HD SCREW E2624A i M4 x 8 POZI PAN HD SCREW en EUR a E2624A QTY 2 HORIZONTAL BARCODE M3 x 8 CAP HD SCREW TRANSPORT PLATE E2503A QTY 2 ae B9171A Fig 19 Horizontal Barcode v Upgrade Kit A3293A or A3297A K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting Page 15 of 28 3 1 Fitting a vertical barcode assembly to the machine I Page 16 of 28 Remove the RH side cover and open the LH side cover Remove the tower access assy this is not essential but is quick to do and greatly improves access the tower ac cess assy is the pivoting section at the top front of the tower The pivot bar is retained with a screw at each end and a nylon strap Remove the paper tranport plate op posite the tower access assembly this is retained by 2 screws on the lower edge 1 screw on the LH side Note that the plate will be different depending on whether the machine is a 3 tray or a single tray both are retained similarly Als
11. Top tray ID 1 is connected to channel 1 ID 2 to channel 2 Middle tray ID 1 is connected to channel 3 ID 2 to channel 4 This should be followed whether there is 1 read head or 2 on each tray Twin read heads If twin heads are fitted for 2 track OMR these can be fitted on the top or middle tray but not both They are connected to channels 1 amp 2 on the top tray 179 8540 to channel 1 179 8550 to channel 2 or to channels 3 amp 4 on the middle tray 179 8540 to channel 3 179 8550 to channel 4 See also Fig 26 on page 18 Page 9 of 28 2 4 DS 100 Configuration see 2 5 for DS 140 configuration L 3 Page 10 of 28 The machine must now be configured so that the OMR or barcode reader is rec ognised Switch on and enter Engineer mode In Configure System repeat edly select continue until the settings for the OMR reading unit appear Assign readers by channel number as shown in Fig 8 below Ch 1 4 are for OMR Ch 9 amp 10 for barcode 2D see also Fig 26 Module 4 P Ch 1 Rdr Ch 2 Rdr Ch 3 Rdr Ch 4 Rdr D Ch 9 Rdr P Ch 10 Rdr gt Accumulator Fitted gt Divert Fitted gt Continue Fig 8 Enter Module Settings in Engineer mode and select the relevant OMR or barcode reading unit s Calibrate OMR Gate 1 and or 2 sensors as shown in Fig 9 below Check that the voltage shown circled is O 5v with no paper between Note that Gate 1 is top tray
12. characters are used Make selections as required to define each character position number of characters if using BCS or the state Enable Disable Ignore if using Neopost 3 When all marks are defined select Done Naming the job After editing the marks you move to the Save screen which allows you create a new name for a new definition or simply press x if edit ing an existing one you will be asked to save before exiting the edit mode NEW NAME To enter a new definition name use the Scroll Up Down buttons to select the first charac ter then press v This moves to the second character and so on up to the maximum 10 characters When finished press x to exit the screen Confirm your changes and your new definition is now saved All OMR definitions created in Engineer mode will be available to the operator for selection when creating jobs that use OMR stationery DS 100 140 OMR amp Barcode Mounting
13. connectiv ity of the readers with their part numbers the top or middle tray of the tower folder FEDER FOLDER MARK READING FEEDER E 182 781 MS 3 I F PCB eae pe CHANNEL 9 diis Tee te We 3 READER CABLE 182 8140 za QA 00 m i L DM100 I F PCB MA CHANNEL 9 e DI diab READER ZIN 2D DATAMATRIX a x O MS 3 I F PCB oa me CHANNEL 10 E Lo o kn FOR MS 3 MODULE PCB PW M i oe ZIN READER BARCODE ka PONES cae HEA
14. double pole fused If fuse failure occurs electrical machine parts can still carry voltage 1 2 Electrical Specification DS 100 140 230VAC 115VAC Frequency 50Hz 60Hz Input Current Head 1A Head 2A Feeder 0 5A Feeder 1A OMR Feeder 0 5A OMR Feeder 1A Tower Feeder 0 5A Tower Feeder 1A Tower Folder 1A Tower Folder 2A Feeder Folder 0 75A Feeder Folder 1 5A Fuse Rating T6 3A T10A Insert Head For full specifications see the complete Specifications document for the machine K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting Page 3 of 28 SECTION 2 FITTING AN OMR HEAD 2 1 Introduction This document describes the fitting of an OMR or barcode reader to a 100 or 140 tower unit It describes upgrading a non reading machine and also provides information such as head align ment calibration and OMR barcode definitions for existing reading enabled machines 3 Tray Tower Folder OMR on station 1 only Kit 9100003U A3247A Fig 1 on the following page shows the assembly of the parts prior to fitting to the machine If not already built when received assemble parts now Tower OMR Bar C9382A with head foot assembly fits into the Tower Access assembly as described later Note that RH top read is shown if bottom read is required the positions of the OMR head and foot assembly opposite are swapped If LH is required the OMR head foot are assembled at the other end of the slider bar The location along the bar of th
15. transport plate C Fig 27 4 At the rear of the machine remove the upper hopper Assemble the scanner to the bracket as shown in Fig 29 Note that there are different hole positions depending upon requirement Generally the scanner should be as far away from the paper as possible moving it to a more forward position if the barcode is very dense or other read problems oc cur Si Fit the M4 x 12 Cap Head screw to the scanner bracket but do not tighten at this stage Slide the bracket onto the bar and fit it into the rear of the ma chine as shown in Fig 30 Note The bar is retained with 1 screw at the RH end to access the hole remove the bracket for the upper splitter PCB and move this clear of the hole do not disconnect cables see 3 1 step 8 Replace the bracket when the screw is tightened cont on page 20 DS 100 140 OMR amp Barcode Mounting Connections are also shown for the standard or 2 track OMR reader and the SICK KT3 OMR reader as this may be used in conjuction with a barcode reader and would affect its connec tion Note that the SICK reader can only be used on the mark reading feeder not the tow er folder 2 track OMR readers can be fitted to OMR amp Barcode Reader Connection There are two barcode reader types available Microscan MS 3 and Cognex DM 100 the DM 100 is primarily used as a 2D Datamatrix reader but can also be used for barcode read ing The diagram below shows the
16. tray is removed the beam can be seen from the rear the hopper interlock detects when the hopper is removed and switch es on the scanner Wind a piece of OMR printed paper into the rollers so that the barcode passes the beam Slide the scanner bracket until the beam is cen trally aligned on the barcode and tighten the screw See also section 4 on the following page Note M3 x 10 Pozi Pan Head screws are shown using Cap Head screws instead will allow adjustment in situ Fig 29 6 Refit the tower access assembly re member to fit the nylon strap 7 Fit the laser warning label to the in side of the tower access assembly after degreasing the surface see Figs 19 amp 19 Connection 8 The procedure for connecting the scan ner is identical to the procedure for vertical barcode This is described in 3 1 steps 10 amp 11 Configuration 9 The procedure for configuring the ma chine is identical to the procedure for vertical barcode This is described in 3 1 step 12 Page 20 of 28 K4 0068 A Issue 5 June 2011 DS 100 140 OMR 8 Barcode Mounting SECTION 4 OMR BARCODE ALIGNMENT amp CALIBRATION 4 1 OMR head alignment 100 Series This is described in detail under section 2 3 step 15 4 2 OMR head calibration 100 Series This is carried out from Analogue Sensors in Engineer mode Select this from the Module Settings for the module that has the head fit ted ANALOGUE SENSORS 4
17. 10 CAP HD SCREW B7645T j NOT PART OF VERTICAL M4 WASHER E2500A QTY 2 i P BARCODE ASSEMBLY E4011A QTY 2 M3 WASHER y lt E4009A QTY 2 au _ A3 0375 BBV l E d su x D ye A ud 9 pa l x sen VERTICAL BARCODE MOUNT BRACKET Pa E R2951A j M EM Qu ge gr d NR M4 x 12 CAP HD SCREW i pp s x ETSI ye a P md 5 j DATAMAN 100Q 2D READER gi VERTICAL BARCODE w j 179 8460 SLIDE BRKT MCN JP i DETAIL OF 2D DM TRAY 1 LUE R2952A Qe ae A3 0375 DBX y a 277 7 LASER CAUTION LABEL l g Pd G3363A SKI CLAMP PLATE OP R2957A BARCODE SCANNER MS 3 179 764 W TOWER ACCESS LATCH R2033F NOT PART OF VERTICAL BARCODE ASSEMBLY A3 0375 BBV SKI LOCATION PLATE OP R2955A Ha PAPER SKI NARROW B9169A T p SKI WIDE DR M4 x 8 POZI PAN HD SCREW E2624A n SKI SLIDE BAR C9677C PAPER SKI SLIDE BRACKET R2953A QTY 5 p NN d e LOU 3 n SKI LOCATION PLATE DR m oe bc e VERTICAL BARCODE GUIDE PLATE R2954A EAT S Ej PAPER SKI NARROW B9172A gt a a B9169A 8 O ad Bi 9169 M4 x 10 CSK POZI SCREW P J m E2711A QTY 6 PAPER SKI WIDE OP 3 z l E M4 x 8 POZI PAN HD SCREW E2624A IAN B9170A M4 x 8 POZI PAN HD SCRE E2624A NOTE PAPER DEFLECTOR PAPER SKI NARROW ki C7401A IS USED FOR a SKI CLAMP PLATE DR B9169A ER R2956A VBC SEE 4c 24 3 ST M4 x 8 POZI PAN HD SCREW RID M4 x 8 T T SCREW a E2701A QTY 4 prece E2624A Fig 18 Vertical Barcode Upgrade Kit
18. 100 140 OMR amp Barcode Mounting Instruction TABLE OF CONTENTS 1 Safety NOEGS seeks uua ES doi DEAE MR CR E a Rp DR D RR A CR Rn RR 2 dl PEO NNA c EE UU I TIT 2 l2 Bleciical SPECI Call OM apa tes a east et a at na pe app ap e ni e pt 3 2 Fitting an OMR Head isaivasaanikontasssnosanaosonenzaegaseneogasnsantsa anko aaaskeNSNs 4 ME isgerliro uic RM tT 4 2 2 PSEETUEIIDOES e koi ie kte babe Eutrop Mc scu ab EUM ERA VUE DEINER E MM DS 4 2 3 Fitting the OMR assembly to a tower unit top tray 7 22 S100 Configuratii santi via oo ei pata at re e mta eis katab l ea a Saw rV 10 2 5 DS 140 configuration ii sit vi ti n aaa ak kak kk kas aa ped pan a a an ta dan ri d A a a A A 10 2 6 ray tower with cascade iiziw saaa kran SR RE Y po app kak a e ANI E Nw 11 27 Ndie ky TOW Ek t t fk ea IAE kr ke a ONE canna BF e re UN kb ga S 14 3 Fitting a Barcode Hedd us ina suia eR CIA E ana ma m CER ER SUECIAE D RN 15 3 Fitting a vertical DIFCOUC est aaa ni oi ate leta VM EO FH rev d eT PEE 16 3 2 Fitting a erzontal DaFeotGG ceceepuresztcxutrupux peu UE xev RE RS C QUEE 18 4 OMR Barcode alignment amp calibration 21 4 1 OMR reader alignment 100 series eene 21 4 2 OMR reader calibration 100 series eeeeee eee 21 4 3 OMR reader calibration 140 series eere esee 21 4 4 Barcode reader calibration 140 series
19. 8478X A3 0375 OTLF OMR flex top left station 1 100 only e 9108479Y A3 0375 OBRF OMR flex bottom right station 1 100 only e 91084802 A3 0375 OBLF OMR flex bottom left station 1 100 only e 9108474T 03 0375 TTR Dual track OMR Top right station 1 e 9108473S 03 0575 7 TL Dual track OMR Top left station 1 e 9108472R 03 0375 TBR Dual track OMR Bottom right station 1 e 91084710 03 0375 TBL Dual track OMR Bottom left station 1 e 9105732M A3 0376 OTR OMR advanced Top right station 2 e 9105733N A3 0376 OTL OMR advanced Top left station 2 e 9105734P A3 0376 OBR OMR advanced Bottom right station 2 e 91057350 A3 0376 OBL OMR advanced Bottom Left station 2 Page 4 of 28 K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting e 9108483C A3 0376 OTRF OMR flex top right station 2 100 only e 9108484D A3 0376 OTLF OMR flex top left station 2 100 only e 9108485E A3 0376 OBRF OMR flex bottom right station 2 100 only e 9108486F A3 0376 OBLF OMR flex bottom left station 2 100 only e 9105731L A3 0375 DBX 2D reading from bottom 140 only Feeder reading not available on 100 e 9105739U A3 0378 OTX OMR advanced from the top e 9105740V A3 0378 OBX OMR advanced from the bottom e 9105741W A3 0378 BTH Barcode advanced horizontal from the top e 9105742X A3 0378 BBH Barcode advanced horizontal from the bottom e 9105743Y A3 0378 DTX 2D reading from the top Feeder Folder reading not available on 100 e 9105746B A3 0379 OTR OMR adv
20. D ID 2 USE FOR STANDARD MAN READER OMR CABLE 182 782 SICK OMR CHANNEL 2 E HEAD ID 2 USE FOR SICK KT3 ZIN READER OMR IF CHANNEL 9 IN USE CABLE 182 782 DOE qu EAM CHANNEL 1 capis HEAD ID 1 USE FOR SICK KT3 N READER OMR AS DEFAUL ES or lac HEAD ID 1 USE FOR STANDARD N READER OMR TOWER FOLDER EUR 2 TRACK TOP TRAY roa CHANNEL 2 179 8550 a TOP TRAY USE FOR 2 TRACK SWE MAN READER OMR READER A m F 199794 LEE USE FOR STANDARD ZN men Fa GONE 4 ZIN READER OMR 179 8540 DEA UH d USE FOR STANDARD OUR E CiN READER OMR READER IN Lo 179 724 USE FOR STANDARD MAN READER OMR O CABLE 182 781 MS3 I F PCB o me CHANNEL 10 ae Eau re FOR MS 3 MAN READER BARCODE CABLE 182 732 D ai CHANNEL 9 PP HEAD ID 179 764 EXPANSION PCB USE FOR MS 3 180 768 N READER BARCODE CABLE 182 8150 bm100 I F PCB A CHANNEL 9 180 8250 Ro y HEAD ID 1 3 PLATE FOLD USE FOR DM100 READE 180 724 ZAN 2D DATAMATRIX MIDDLE TRAY n o CHANNEL 4 nee HEAD ID 2 SHE 2 RACK MIDDLE TRAY a ar eae D CHANNEL 4 TUBE js eee E TRACK OMR A READER OMR READER qu ENN 7 179 724 s MIRRORED USE FOR STANDARD OMR MAN READER OMR E m CHANNEL 3 179 8540 ded USE FOR STANDARD MAN READER OMR K4 0068 A Issue 5 June 2011 Fig 28 DS 100 140 OMR amp Barcode Mounting Page 19 of 28 Retaining screws 10 The scanner beam must now be aligned for scanner with the barcode Switch on the machine and providing the upper hopper
21. MR calibrate 3 4 0 B mod 1 hopper 1 id 1 INFORMATION Position beam just before an OMR mark Press tick to continue X has been successful Press tick to finish If the calibration consistently fails the mark contrast is too weak DS 100 140 OMR amp Barcode Mounting 4 7 Barcode reader calibration 100 Se ries Calibration of the barcode reader is carried out from the Run screen with the machine paused Press the X button to reach the op tions then select Barcode Setup as shown below Follow the on screen instructions Note that the Barcode setup option will only appear if a job that uses a barcode marked docu ment has been selected Results displayed as below are a read only report of reader head efficiency BARCODE SET UP gt mode b _L__d P BAEC 0 5 BARCODE SET UP p mod 4 hopper 1 id 1_ P mode read Fl b mo i gt IBAJVECACGACAAGAAAABBCCDDE mod 4 hopper 1 id 1 gt mode decodes s gt 1000 Decodes Sec b IBAJVECACGACAAQAAAABBCCDDE b IBAJVECACGACAAQAAAABBCCDDE Switch Mode between read which should be 100 decodes s which should be 1000 or label in terpretation only If results are lower than above figures read reliability will be impaired The lowest line shows the barcode label characters If any furthe
22. OddO Q32V ld jd LSNW SASSY LOOJ YWO 440 Z AILLI FAV SAVITH YWO HAIVAL Z N3HM 3 LON L ALO vosgzg H1 31vId NOILVOOT SAD vi0OZZ3 IZL 8 X PW MIYOS udi L AIO vS0SZ3 gn49 9 X PW MIYOS AIO Tv 6 l Qv3H SNO L ALIO vese avq YANO S8JM0 L ALIO v659 H HM Fivld NOILVOO1 C AO VAZEGD V8 SWO N3MO L ALIO V6 0 M HM dlVid dNvIO VSGOGC3 9 X PW MANOS g8nso9 di VBSEE S X NYa OL X GW MANOS X L vc 019 IZOd MSO OL X PW MANOS ane wi A ONIMdS A 7 wl8199 4 i CA ASON Jen e pw ig ai AID yooeza S AV YLOLZ3 YNO CONV ATAWIJSSY SIHL 40 E ava gnyo 9 X BW M3NOS L l 8 X vM MINIS SNOLLVOO1 dV e NO Log dO wo l X 91 1 NldMIO vz9192 pd NOUIS S CV guo 19 Pal 004 AWO n boo VILZZ3 LHI a Sec Li IZOd MSO OL X PW MIYOS e NOLEVIS wu VANIS VEQOGLY ASSV LOO04 ano DS 100 140 OMR amp Barcode Mounting K4 0068 A Issue 5 June 2011 Page 12 of 28 Fitting the OMR assembly to the machine for Cascade At this stage it is assumed that the machine will still have covers and tower access assem bly removed as described in section 2 3 and that station 1 OMR assembly has been fitted as described For station 2 proceed as fol lows 1 K4 0068 A Issue 5 June 2011 On the RH side remove the the gears shown in Fig 16 below This provides access to the end of the transport roll
23. The OMR job is now ready to be run If OMR read problems are encountered see section 4 2 7 Single Tray Tower Kit A3266A The procedure for single tray machines is exactly the same as section 2 3 for 3 tray machines with OMR on one tray only except for the OMR Access bridge shown in Fig 5 This is replaced by B7614A and is supplied in the kit Note that the pictures shown in section 2 3 will differ slightly from the single station ma chine but all actions will be the same Page 14 of 28 K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting SECTION 3 FITTING A BARCODE HEAD Machines not fitted with a Barcode reader can be upgraded to full barcode specification by or dering the appropriate kit of parts A3292A Vertical Barcode Upgrade Kit 3 tray machines A3293A Horizontal Barcode Upgrade Kit 3 tray machines A3296A Vertical Barcode Upgrade Kit 1 tray machines A3297A Horizontal Barcode Upgrade Kit 1 tray machines Both vertical and horizontal use the same scanner 179 764 though 2D barcodes use 179 8460 For a 3 tray tower the assemblies can only be fitted to the upper tray The single tray kit differs by including an Expansion PCB and ribbon cable needed for connection these are fitted as standard on 3 tray machines Barcode and OMR cannot both be fitted on the same tray For part numbers when Barcode reading is specified at the time of order see page 1 TOWER TOP COVER A an M3 x
24. ading problems contact Technical Support department Page 24 of 28 K4 0068 A Issue 5 June 2011 SECTION 5 OMR AND BARCODE LICENCE amp DEFINITION FOR 100 SERIES Important this section must be read in conjunction with the OMR or Barcode Specifications document for 100 140 Series 5 1 Entering the licence key This procedure assumes that the licence key has already been obtained This key must then be entered into the software before an OMR or barcode definition can be created Enter Engineer mode and select Licence Set up ENGINEER Module Settings Insert Head gt Burn in Mode Env Only Mode Set Default Supervisor PIN P view throughput LIS OL Sensor Cal Super D CONFIGURE SYSTEM Licence Set up W zh Select Enter Licence Key LICENCE Machine ID BH3G UN 24 DAA bEnter Licence Key Feature Set 0 0000 0000 0000 2 This will allow the key to be entered as shown opposite DS 100 140 OMR amp Barcode Mounting LICENCE To enter the licence key use the Scroll Up Down buttons to select the first character then press v This moves to the second character and so on up to the maximum 10 characters When finished press x to exit the screen When the conformation screen ap pears press v to exit You should now see that Feature Set is no longer shown as zeroes see below The number will reflect the licence entered and is generated by the software
25. agnostics then Analogue Sensors tab Calibrate the OMR Gate as shown in Fig 13 be low Repeat for any other OMR barcode hoppers save and exit Engineer mode Engineering Diagnostics The machine is now ready for operation cam x Exit Fig 13 4 Enter Configuration and select the required setup Select Edit then select the appropriate hopper of the mark reading unit Set Mark Reading to OMR Marks or Barcode as required set Fold 2 6 3 Tray Tower with Cascade Kit 9100004V A3248A Cascade OMR is the fitting of an OMR head to hopper 2 on a Tower Unit The procedure described in section 2 3 must first be carried out in full with the exception that the tower access assembly is not refitted until the actions described in this section are carried out Fig 15 on the following page shows the assembly of the parts prior to fitting to the machine If not already built when received assemble parts now Note that RH top read is shown if bot tom read is required the positions of the OMR head and foot assembly opposite are swapped If LH is required the OMR head foot are assembled at the other end of the slider bar The loca tion along the bar of the OMR head depends upon the required approximate position to align with the marks on the paper Wherever it is located the sliders C6223A should be roughly evenly distributed about it K4 0068 A Issu
26. aining screws for scanner Note M3 x 10 Pozi Pan Head screws are shown using Cap Head screws instead will allow adjustment in situ Fig 22 DS 100 140 OMR amp Barcode Mounting Connection 10 Slide the bracket assembly with scanner Scanner Expansion PCB onto the barcode slide bar and assemble cable and ribbon cable this into the rear of the machine see Fig 23 below The bar is retained with 1 screw at the RH end to access the hole remove the bracket for the upper splitter PCB and move this clear of the hole do not disconnect cables See Fig 24 below Replace the bracket when the screw is tightened Chassis cutout for cable Extender cable Fig 25 connected to J7 Interface PCBs 11 Ifan MS 3 reader is being used an I F PCB will be needed for connecting CH 10 but not for CH 9 which connects to the Expansion PCB If a DM100 reader is being used for 2D a different I F PCB will be needed see Fig 28 for connec tion Assemble the PCB using supplied spacers as shown in Fig 26 below Normally only one PCB would be fit ted but if both MS 3 CH 10 amp DM100 readers are fitted both PCBs are piggy backed together using supplied spacers Fig 26 below shows both PCBs fitted Interface PCB s Slide bar retaining oplitter PCB screw bracket Fig 24 Fit the laser warning label to the in side of the tower access assembly after degreasing the surface see Figs 17 amp 18 Rout
27. anced top right e 9105747C A3 0379 OTL OMR advanced top left e 9105748D A3 0379 OBR OMR advanced bottom right e 9105749E A3 0379 OBL OMR advanced bottom left e 9105750F A3 0379 BTH Barcode advanced horizontal from top e 9105751G A3 0379 BTV Barcode advanced vertical from top e 9105752H A3 0379 BBH Barcode advanced horizontal from bottom e 9105753 A3 0379 DTX 2D reading from top K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting Page 5 of 28 Ajuo T uonei3s VZpc v NEOOOOT6 HA AWO A9MOL T Hig b On Y dOL AVML MWO NIML MLLI GZEO EY v ALO VLLZZ3 E v SAID vrz9z3 1 dOL AVML NWO NIML Ml SZ 0 6v IZOd MSO OL X PA MJYIS 8 X PW MANOS Y WIG L AVY O NIML gp bfe0p L ALO vzerso E E MO TOWIS L AVML NO NIML IE C Oo C d l AID voosza NOlLdINM2S3 C N l v HO 9 vA MdidOS SNOILdO NOINSOd M3Qv34 MOVvMI Z 340 157 LALO vZZ 6 4 n Qv3H YNO Z ALD VLZOY3 ALO vosozg o p Mm OOMd S YSHSVM EN H1 31vIld NOILV207 P uM d N Z ALO VLT9Z3 ll rer i L AIO OrS98 6 1 NVa 9 X N Mass NL A
28. e 5 June 2011 DS 100 140 OMR amp Barcode Mounting Page 11 of 28 9 ALO v60GSC3 9 X PW MANOS ANYO G AIO YEZZID 830llS YANO L AIO vssocy H1 3IVld dWv1D LALO vesoza H1 3Ivla NOILVOOT AIO Vv 62 avga JNO 8J3MO1 L ALO VLOZZ3 IZL 8 X N MIYOS l AIO v 99 8 C AIO vieorv jOONd S d3HSVM C ALE Versa Nvd 9 X EW M3MOS L ALO POLZ GLI aJOVONI V8tC V AvOOOOTG6 1D VWO 9pe5se ABMOL ST By L AIO vIOZ23 IZL 8 X PW MIYOS G ALO vesoszi Z AIO vSsosci gnd9 9 X VW MIYOS 6 AIO vcSe99 aJdris 4OSNdS SNO 9 X vA MANOS 8nWuo9 G AD vegi9J a3Jaris YANO LNOILVIS SV SAJLI AVML JIGGIN YO dOl X04 lvNOILdO Que See id MJOVJM MOVMI Z i i AIO OvS8 6 1 o OJFYOYYIN AVIH MINO AID viOZ23 l 9 L A SAA E AIO OSS8 64l 7 l M3MOT LING YOSNIS NM ae e P4 L AS es l INAYO 9 X PW MIYIS ALD V6gOcH qu Xt H1 3ivld dWv19 Qv3H WO G ALO Wezeso MJOlIS YWO L ALD v9SoZH iyid NOIIV201 L AIG arctic Z AIO WLZOVF Fwd dWv12 JOOMd S M3HSVM 6 ALO VLY96CJ Nvd 9 X FW MIHIS L ALO Oe oe S AIO VILL LIM NI GAGNIONI 31IS
29. e OMR head depends upon the required approximate posi tion to align with the marks on the paper Wherever it is located the sliders C6223A should be roughly evenly distributed about it 2 Track OMR The optional 2 track OMR scheme has two rows of marks side by side and hence two read heads instead of the standard single head 2 2 Part numbers Machines not fitted with OMR can be upgraded to full OMR specification by ordering the appro priate kit of parts 9100003U A3247A 3 Tray 3P Tower Folder OMR on Station 1 only 9100004V A3248A 3 Tray 3P TowerFolder OMR on Stations 1 amp 2 cascade 9100005W A3266A Single Tray 3P Tower Folder Also available is 9101714B A3261A OMR Head 8 Foot Kit This comprises the OMR head together with the aluminium foot with spring loaded nylon shoe The full upgrade kits also in clude all brackets sliders and slider bars Part numbers when OMR or Barcode is ordered with the machine If the OMR or Barcode reading is specified as an option at the time of ordering the machine the following part numbers will supersede the above numbers unless stated otherwise number apply to 100 amp 140 Tower Unit e 9105725E A3 0375 OTR OMR advanced Top right station 1 e 9105726F A3 0375 OTL OMR advanced Top left station 1 e 9105727G A3 0375 OBR OMR advanced Bottom right station 1 e 9105728H A3 0375 OBL OMR advanced Bottom Left station 1 e 9108477W A3 0375 OTRF OMR flex top right station 1 100 only e 910
30. e the scanner cable through the chassis cutout shown in Fig 23 and l retain it using existing chassis clips Fig 26 as shown in Fig 25 opposite Connect the extender cable to the scanner cable Single tray machines only and attach this to existing ribbons us ing cable ties Connect the cable to J7 on the expansion PCB either barcode or 2D see opposite for single tray machines Single tray machines are not fitted with an Expansion PCB as standard hence the upgrade kit includes this item together with 4 spacers with screws for mounting it and a ribbon cable for connection To fit the Expansion PCB remove the screw in each corner of the main PCB and lift it away from the chas sis sufficiently to insert and tighten the K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting Page 17 of 28 M4 x 6 Cap Head screws for the spac ers Refit the main PCB and assemble the Expansion PCB to the spacers using M4 x 6 Cap Head screws Connect the ribbon cable between main and Expan sion PCBs as shown in Fig 25 See also connection diagram Fig 28 on the following page Machine configuration 12 After fitting the barcode scanner the machine must be configured to recognise it The procedure for both 100 and 140 series is described in section 2 4 Scanner alignment 13 The scanner beam must now be aligned with the centre line of the barcode Switch on the machine and provid ing the upper hopper tray is rem
31. eader and the decoded data The read should be as near 100 as possible and while a figure below this may well work quite acceptably steps should be taken to try to increase the read quality Moving the scanner to a position closer to the paper may well increase the percentage otherwise the print quality of the barcode should be looked at see step 11 below APRES tate foul 5 0 10 File ComPort Download BootLoad Engineer OmrScope JobsiSettings Help Rx Start Log Stop Log Off F8 BC 100 BCAAEF Flags BC 100 BCAAEF ee 9 9 9 9 9 9 9 9 9 ee 9 9 9 s 9 9 9 9 9 9 9 9 s 9 9 9 9 9 9 RC 1nn amp RCAARF To capture an OMR trace select Omr Scope then Save as bitmap to save to a chosen filename and directory This can be used for analysis by Technical Support department Test run the machine with representa tive paper If read errors are occurring or if the barcode quality is poor eg bad or too dense printing move the scanner further forward on its bracket see step 4 The scanner should be as far back as possible without read er rors Note to preserve scanner life the beam is actuated only when scanning a barcode printed page thus it is actually switching on and off rapidly as docu ments are processed It is also switched on when the upper hopper is removed to allow alignment For further assistance in diagnosing OMR or barcode re
32. er shaft and extrusion screws Remove these gears Remove the E clips T bearings and springs from both ends of the transport roller shaft and lift it out of the chassis In its place fit the OMR transport roller shaft A2844A supplied in the kit Assemble this with the nylon encoder mount P2150A in place of the TI bearing on the LH end Note that the stepped end of the shaft runs through this mount Assemble the encoder base plate to the nylon mount using 2 off M3 x 6 screws amp lockwashers see Fig 15 On the en coder cover align the small grub screw hole with the slot on the curved part of the cover and insert the Allen key this is normally supplied with the Allen key in place Clip the cover onto the base and tighten the grub screw onto the end of the transport shaft Pull out the Allen key and turn the adjustor slot fully clockwise to position 2 Note when the encoder cover has been clipped in place it cannot then be removed 4 9 10 DS 100 140 OMR amp Barcode Mounting Connect the supplied encoder cable 182 703 from the encoder to the upper Splitter PCB on the LH side Top tray Wires are connected BLK WHT to J1 RED BRN to J2 Middle tray Wires are connected BLK WHT to J3 RED BRN to J4 Remove the infill cover and pivot plate shown in Fig 17 below Also remove the paper tranport bridge just below the infill cover and the extrusion under it Infill cover and pivot plate Paper tra
33. er tray and move the OMR shoe in the tower unit out of the way so the OMR head is visible by looking through the tray aperture Wind in the paper and align the head using the same principle as for bottom read When aligned move the OMR shoe back so that it is opposite the OMR head and distribute the slid ers evenly Tighten all grub screws and replace the cover plate when finished DS 100 140 OMR amp Barcode Mounting Note the OMR reader is not central within the window the centreline of the marks must align with the head as shown in Fig 6 below SINGLE TRACK Alignment marks cest Ee 2 RACK Fig 6 OMR channels 16 K4 0068 A Issue 5 June 2011 The machine can support up to 4 OMR heads in any combination The heads are assigned a channel number in the software which can be changed if re quired The channel number equates directly with the PCB connector that the head is plugged into see Fig 7 oppo site DS 100 140 OMR amp Barcode Mounting Channel 1 Channel 2 Channel 3 Channel 4 Fig 7 Note that channels 3 amp 4 are located on the expansion PCB this will only be fit ted for machines with more than 2 OMR heads fitted or for cascade machines ie 3 tray units see section 2 6 for cas cade OMR The read head IDs are identified as 1 and 2 on both top and middle trays viewed L 8 R from behind respec tively
34. f M3 x 6 screws amp lockwashers see Fig 1 On the en coder cover align the small grub screw hole with the slot on the curved part of the cover and insert the Allen key this is normally supplied with the Allen key in place Clip the cover onto the base and tighten the grub screw onto the end of the transport shaft Pull out the Allen key and turn the adjustor slot fully clockwise to position 2 Note when the encoder cover has been clipped in place it cannot then be removed Connect the supplied encoder cable 182 703 from the encoder to the upper Splitter PCB Wires are connected BLK WHT to J1 RED BRN to J2 DS 100 140 OMR amp Barcode Mounting Fit the supplied emitter RED BLK wires to the sensor mount on the supplied OMR bridge B7649A Remove the exist ing paper transport bridge below the transport roller shaft the OMR bridge will fit in its place after fitting the OMR assembly Fig 4 below shows the OMR bridge in place Fit the OMR assembly and retain it with 2 screws each side on the outside of the chassis as shown in Fig 3 below If the OMR head is fitted to the assem bly lead the cable through the chassis bush shown in Fig 3 Retain the cable through existing clips and connect to J14 OMR 1 on the main PCB Bush for OMR assy emitter wires screws 3 r 4 J a i Bush for OMR head and receiver wires Fig 3 Fit the OMR bridge B7649A leading the emitter wires through the bu
35. le the tower access assembly to the machine leading the receiver OMR head cables through the bush shown in Fig 3 Ensure the restraining strap on the assembly is in place Note if station 2 OMR cascade is also being fitted do not fit the assembly at this stage See section 2 6 for fit ting cascade OMR If the OMR head is fitted to the assem bly retain the cable through existing clips and connect to J14 OMR 1 on the main PCB Connect the receiver to the supplied link cable 182 622 and connect this to J7 on the upper splitter PCB Align the OMR head to suit the marks on the paper with the sliders evenly dis trubuted as shown in Fig 1 The grub screw for retaining the OMR head tight ens onto the slider bar which attaches the head to allow access for adjustment To align the head for bottom read head fitted to tower mark the edge of the reverse side of the paper to align with the centre of the marks either single or 2 track Wind the paper into the hop per by turning the pickup roller and the green knob Slacken the grub screw and slide the head to align the marks as shown in Fig 6 note that 2 track heads have an alignment mark To align the head for top read head fitted to opening cover open the cover and remove the inner cover plate to provide access to the grub screw unclip the gate sensor as it is withdrawn and be careful not to open it too far with the restraining strap removed Now remove the hopp
36. ncrement W tk Page 27 of 28 Note A full description each mark can be found in the Barcode Specifications document for 100 140 Series Machine control Options are BCS CUS TOMER ID NEOPOST 3 LAST PAGE this is for legacy use only Symbology Only 3 of 9 is available at first release 2 of 5 and Code 128 on later ver sions Characters in label Up to 25 Grouping Options are End of group First of group Form or Group seq start count Options are O or 1 Form or Group seq count dir Options are Increment Decrement Customer ID start pos Selectable up to a maximum of the label length Customer ID length Selectable up to a maximum of the label length When all selections are made select Done and you will move to Edit Label Example for BCS EDIT LABEL BCS 1 b Grouping Char Pos P Selects Item 1st Char Pos P Selects Item No of Chars gt Divert Char Pos Form Security Char Pos P Group security Char Pos Matching Char Pos Done Example for Neopost 3 EDIT LABEL BCS 1 Page N of M Disable T gt Page N of M chars i Tal gt Sheet Seq Disable T P Sheet Seq chars gt GroupSeq Disable F To W Disable _ Disable e P GroupSeq chars P Insert gt Accumulate Page 28 of 28 K4 0068 A Issue 5 June 2011 Note that for machine control Customer ID there is no edit screen as no other
37. nsport bridge Fig 17 Fit the new extrusion C7401A but do not fully tighten the screws Insert 3 sheets of 80gsm 20lbs bond paper between the extrusion and the white roller below it Bias the extrusion so that the pa per just fits in the gap and tighten the screws Check that there is slight drag on the paper as it is pulled out of the gap Fit the new OMR transport bridge B7670A in place of the paper transport bridge On the OMR assembly ensure that the gate sensors are in place and correctly connected RED BLK wires inside the tower unit Fit the unit into the tower feeding the sensor and OMR head wires through the plastic bush on the RH side On the LH side ensure the pip on the assembly side plate locates into the notch in the chassis edge Refit the infill cover and pivot plate Refit the tower access assembly as de scribed in section 2 3 step 13 Page 13 of 28 Connection 11 Using the supplied 182 352 extension lead connect the sensor wires to the middle station 2 splitter PCB on the RH side YEL BLU to J7 RED BLK to J8 12 Connect the OMR head as described in section 2 3 step 16 If one head is fitted at station 2 connect to channel 3 If two heads connect to channels 3 amp 4 13 Use cable ties to secure added wires and cables away from any moving parts snag points or sharp edges 14 Follow the Engineer and job setup in structions described section 2 4 15 Replace all covers
38. o remove the extrusion see Fig 20 that the paper transport plate attaches to 2 screws at each end and fit the replacement item Note that to access the screws on the LH side the gear idler must be removed as shown in Fig 21 opposite Assemble the paper skis location plates clamp plates and ski slide bar as shown in Fig 18 on the previous page but do not tighten the M4 x 25 screws at this stage Slide the assembly into the cavity of the machine as shown in Fig 20 below Retain the LH end using 2 screws as shown Fit the guide plate so that the angled flange is under the tips of the skis Paper ski assembly Retaining screws Guide plate attached to new extrusion Fig 20 K4 0068 A Issue 5 June 2011 At the RH end remove the idler gear shown in Fig 21 below This will provide access to the 2 screw holes for fitting the retaining screws Refit the idler gear Retaining Stud for idler screws gear kan Remove this idler to access extrusion screws Fig 21 Refit the tower access assembly re member to fit the nylon strap At the rear of the machine remove the upper hopper Assemble the scanner to the bracket as shown in Fig 22 below Note that there are different hole posi tions depending upon requirement Gen erally the scanner should be as far away from the paper as possible moving it to a more forward position if the barcode is very dense or other read problems oc cur Ret
39. ount gt Reverse seq order LI Invisible gate mark bh fk Page 26 of 28 K4 0068 A Issue 5 June 2011 Note A full description each mark can be found in the OMR Specifications document for 100 140 Series Code type Options are 1 track 2 track Number of marks Up to 20 Gate Mark Options are Top Bottom Left Right Refers to the position of the mark as printed relative to the address printing ie Left and Right refer to horizontal OMR marks Pitch Options are 3mm 3 8mm 4mm 5mm 5 3mm 10mm 1 10inch 1 8inch 1 6inch 1 5inch 1 4inch 1 3inch Parity Options are None Odd Even Form seq start count Options are O or 1 Refers to both Form sequence within a job and Form sequence within a group Reverse seq order Select if marks are to be read backwards eg if paper is loaded the other way up Invisible gate mark Select if used An invisible gate mark allows a single mark on the last page of a group to be used as an end of group mark Pitch will default to 10mm number of marks to 2 invisible gate and printed mark Other functions except Gate mark to indicate position will be null Applies only to 1 track Diverti and Divert2 Select event to occur if divert mark is used Divert2 applies to 2 track only When all selections are made select Done and you will move to Edit Marks EDIT MARKS OMH 1 pWarki ste
40. oved the beam can be seen from the rear the hopper interlock detects when the hopper is removed and switches on the scanner Wind a piece of OMR printed paper into the rollers so that the bar code passes the beam Slide the scan ner bracket until the beam is centrally aligned on the barcode and tighten the screw The angle of the bracket can also be adjusted to allow the beam to run in line with the barcode 14 Remove the paper and from the front of the machine slide the paper skis so that they are approximately equally spaced over the length of the slider bar then tighten the screws Ensure that the beam is not obstructed by any of the skis See also section 4 Page 18 of 28 K4 0068 A Issue 5 June 2011 3 2 Fitting a horizontal barcode assem bly to the machine 1 Remove the RH side cover and open the LH side cover 2 Remove the tower access assy this is not essential but is quick to do and greatly improves access the tower ac cess assy is the pivoting section at the top front of the tower The pivot bar is retained with a screw at each end and a nylon strap 3 Remove the paper tranport plate op posite the tower access assembly this is retained by 2 screws on the lower edge 1 screw on the LH side Note that the plate will be different depending on whether the machine is a 3 tray or a single tray both are retained similarly Fit the new item in its place as shown in Fig 27 below Paper
41. r problems persist with setup or calibration contact Technical Support K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting 4 8 Using Trace Tool 100 series only The Trace Tool uitility is primarily used for downloading firmware and also provides useful information about the machine function and of the degree of read quality It can be used for both OMR or barcode though the OMR Scope function for viewing or capturing a trace is applicable only to OMR reading Connect the computer as described in 3 14 1 of the service manual and set up the reader as described above As the paper is wound into line with the reader this should repeatedly beep if the marks or barcode are being read To determine how well the marks or barcode are read the information area of the screen in Trace Tools will show a percentage good read A reading will be shown only when the eject sensor of the 3 plate folder is blocked most easily performed by lifting the green knob in front of the daily post tray to raise the roller platten as shown below A log of the display can be captured for later analysis by Technical Support Select Start Log and select a directory This will start the capture of the data and stop when Stop Log is selected creating a logfile in the directory Page 23 of 28 An example screen display is below for a barcode In this case this shows the percentage read quality of a barcode r
42. ration described above relates to the barcode for the specific job To carry out diag nosis for any barcode go to the Engineering screen and select Reader setup Press Start align test to turn on the reader and feed the paper in by hand so that the barcode is under the reader Module 5 3p3h Folder Reader on Ch 10 MS3 Reader Head 2 on Hopper 1 100 Yo BBANA1014 41 Page 22 of 28 K4 0068 A Issue 5 June 2011 The vertical green lines should extend from the bottom of the display to the top repre senting 100 read quality Less than 100 will result in shorter lines a poorly reading scanner will produce a histogram effect For further assistance in diagnosing bar code reading problems contact Technical Support department 4 6 OMR reader calibration Mark Read ing Feeder using SICK read head only Calibration of the OMR reader is carried out from the Run screen with the machine paused Press the X button to reach the options then select OMR Setup as shown below Follow the on screen instructions Note that the OMR setup option will only appear if a job that uses an OMR marked document has been selected and the unit is a mark read ing feeder Calibration should be carried out whenever the mark contrast is different from the last job or if read errors occur RUN MRF OMRI b Global Count D MPPC b Job Count DOMR set up PUER OMR SET UP P O
43. s Oo O3YOMYIN OVIH NINO i ALO v0Z 641 dils SNO LN H3009N3 Z AID V 4 62 Dese H 1 di AIS OvdH AWO E vo aa 9 X PW MJYDIS ANAYO 1VNOLLdo M3QV YOVYL Z L ALO V659 H LV la NOILVOO AIO vSscozy V 60 V ON LM AAO TINS So ANMWE SE fw W Wi a DOSA gave 4 v 9195 SU LIM NI GAGNIONI 311I50ddO Q32V ld jd LSNW SASSY 1004 YWO 440 Z GFILLIJ JAV SOVIH YWO AOVUL c NAHM ILON DS 100 140 OMR 8 Barcode Mounting K4 0068 A Issue 5 June 2011 p Me H Ivld diNV 1O ki i Y6SSCI LOOJ 79 UVIH e O J40 SNOILSOdg i Nyd OL X N MIYOS C LIP Vv6963 dvMS qv34 WOLLOS YOL MYE WO J yon 8 X v MJYOIS LHO dOL AV amp ML HNO 10O S7 0 eV QN3 MJ3HIO OL 1004 8 GVSH YANO 3AOW ei wee Ap vero X dol AVYL MWO JM10 9 0 V l1 X04
44. sh shown in Fig 3 Connect to J8 on the upper splitter PCB Slacken the grub screw on each OMR slider and align them as far as possible with the rubber bands on the roller as shown in Fig 4 on the follow ing page Important If centre OMR marks are being used OMR Bridge B3 1366 A must be fitted in place of the standard item Page 7 of 28 OMR foot assembly ex ample shown is top read 13 Emitter OMR bridge OMR assy Fig 4 Tower Access Assembly v 10 Referring to Fig 5 below remove the existing access bridge Fit the square slider bar C9382A as shown in Fig 1 after sliding on either the OMR head for top read or foot assembly for bottom read If fitting the OMR head lead the cable out through the bush ad 15 jacent to the pivot Receiver OMR head on slider bar OMR access bridge Fig 5 Shown fully reassembled 11 Fit the supplied receiver sensor to the OMR access bridge Also fit the 2 sup plied P clips using M4 nuts amp washers then feed the wires through the clips Page 8 of 28 K4 0068 A Issue 5 June 2011 Align sliders with black 12 rubber bands Assemble the OMR access bridge to the tower access assembly leading the re ceiver wires through the bush adjacent to the pivot Refit the top cover The as sembly should now look as shown in Fig 5 Important If centre OMR marks are being used OMR Access Bridge B3 1365 A must be fitted in place of the standard item Reassemb
45. the device does present hazards when worked upon 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 hazard to operators when your work is finished 1 1 Pictograms General Warnings Warning of danger from electricity or electrical shock Warning of laser risk IMPORTANT When any installation or servicing operations are completed ensure that all covers are in place and undamaged Ensure that all mains leads are sound and undamaged PUT SAFETY FIRST Page 2 of 28 K4 0068 A Issue 5 June 2011 DS 100 140 OMR amp Barcode Mounting WARNING This modification must only be installed by an Authorised Service Engineer Upon completion ALL covers must be re fitted and NO moving parts must be left exposed If any fixed cover is left removed the operator must contact the Service Department immediately before attempting to use the ma chine CAUTION Class 2 Laser This device emits laser radiation which may be harm ful to the eyes if not handled properly Do not look directly into the aperture of the device Do not activate the device when it is not affixed to the machine If used as directed there should be no risk of harm CAUTION Risk of electrical shock This machine operates at mains voltage and is
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