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1. DAILY POST HANDFEED TRAY LOADING FED TRAY LOADING WHEN ACCUMULATION TRAY IS USED FORM ORIENTATION BCR RE ON FEED TRA EAD ON BOTTOM FORM ORIENTATION ON FEED TRAY FEED SEQUENCE 140 Operator Manual 11 GENERAL SPECIFICATIONS This document covers specifications for general data form and insert sizes envelope speci fication and physical and electrical data Separate specification documents are also avail able for Barcode Labels and OMR Marks Please note that stationery sizes and weights are stated as a guide specific applications may use stationery of a finish rigidity colour density etc that are unsuitable and may not function correctly Where doubt exists it is recommended that samples be provided to the Technical Support department so that running tests can be carried out to simulate the job requirement If changes are then required this can be established at the outset A range of speci
2. 140 Operator Manual 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 O O A 1D LOWER is Mee J SKEW LOWER WDD UPPER N O SS SKEW UPPER Yo HP LOWER O A O HP UPPER 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 SL Pal 54 140 Operator Manual Tower Unit There are sensors in three locations Open the side cover and swing the green latch upwards to raise ME Aa or the roller platten Clean both SO halves as shown YA AOLD POINT 4 U
3. Body Depth Min 70mm 2 Max 165mm 6 y Throat Depth fu 7 5 Min 89mm 372 Horizontal portion of throat Vax AA 8 m Min 10mm 342 Max Envelope Width 75mm 3 Commercial style envelope Envelope Width Max 264mm 10 Min 153mm 6 a mm Widths from 153mm 6 to 182mm 7 require Narrow Finger Kit A3348A Envelope Weight 70gsm 18lbs bond min 100gsm 26lbs bond max Hopper Capacity Up to 400 of 80gsm 20lbs bond envelopes General Requirements Envelopes to be good quality machine fill envelope Dimensions and quality to be consistent across manufactured batches Windows to be securely affixed to within 1 5mm 1 16 of top and side edges Top edge to be flat and free from puckering Side seams to be securely glued up to top of seam Position of internal side seams to give a minimum 5mm 3 16 clearance or overlap to the edge of any insert Pre scored flap crease to enable the envelope flap to open flat cont 140 Operator Manual 63 Envelope requirements cont 64 No twisting curling or distortion evident No glue seepage on interior or exterior of envelope Paper smoothness 100 200 Sheffield units Large printed areas require approval from the Technical Support Dept Envelopes not meeting the above requirements may be acceptable subject to testing and approval by Technical Support Dept Envelopes not meeting the
4. HOLD PONT 4 LOWER yy With the side cover open swing the green latch forwards to open O the daily post hopper Clean both O Z halves as shown DP Hinge the top cover forwards and HOPPER OA liberally spray the air jet in the gap indicated to ensure both halves are cleaned S 5OUBI JMEN DESK b SY Z lt A WS 140 Operator Manual 9 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 AO276A as this has been specially formulated for greatly enhanced sealing and antibacterial qualities Fill through the spout as shown up to the level indicator Withdraw the tank by using the green tab Check the condition of the sponge at regular intervals and clean off gum residues as 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
5. Standard feeder Insert collate area Envelope hopper Note Station 1 is the first Filled feed unit after the insert envelope tray collate area Storage cupboards PC under insert head Feed trays either 3 or 1 Tower Folder Accumulator optional Forms diverter optional Accumulator sideguide 10 140 Operator Manual 5 OPERATING INSTRUCTIONS 5 1 These Operating Instructions guide you through the stages of using the What s machine The machine is entirely software controlled with all operator in this functions being performed on the touch sensitive control screen Document Different levels of user access can be allocated to personnel so that for example configuration operations can be restricted to Supervisors while operators will only have access to straightforward running of the machine The sections of this document that relate to restricted access are clearly 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
6. 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 140 Operator Manual 140 Operator Manual 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 feeder or dual feeder and is a read only display Indicates the separator position calculated by the software If the physical separator is set differently from this a warning will be flagged for the first insertion cycle on
7. min for module 1 either or both hoppers OMR 89mm 3 min for following modules 152mm 6 max Width 140mm 5 min Widths below 168mm 6 6 require narrow finger kit A3348A 241mm 9 max Thickness 60 gsm 16lbs bond min 2mm 5 64 booklets max top tray 4mm 5 32 booklets max lower tray Notes Inserts must be flexible enough to suit path contraints Some inserts may require special feed tyres Hopper capacity Up to 200 reply paid envelopes or 100 2mm booklets Pack thickness for insertion 6mm 1 4 max Min Insert pack clearance Up to 3mm thick pack Depth 6mm 1 4 Width 14mm 9 16 3 6mm thick pack Depth 10mm 3 8 Width 19mm 3 4 62 140 Operator Manual 11 3 Envelope Specification Minimum open en 1 Flap Length l throat area Max 50 Qn Flap Shoulder Angle Min Throat angle aie mm 50 Min 90 Max 10mm 5 Min 20 Max Min 32mm 174 LM l Body Depth Min 70mm 2 Throat Depth Min 89mm 3 Horizontal portion of throat Min 10mm 133 Max Envelope Width 75mm 3 side Seam style envelope Envelope Width Max 264mm 10 Min 153mm 6 Minimum open a p 2 Flap Length Min inroatarga Max 50mm 2 Flap Shoulder Angle 40mm Throat angle a ea 50 Min 90 Max 34 1 5 Min 20 Max Min 32mm 174 LL A
8. E E E O LO i 140 Operator Manual Feeder Folder Depth 140mm 5 min 89mm 3Y2 for shortforms 406mm 16 max 139mm 5 2 for shortforms Optional Shortform kit A3302A must be fitted if short forms are being used Width 140mm 5 min Widths below 168mm 6 6 require narrow finger kit A3348A 229mm 9 max Thickness 60gsm 16lbs bond min 70gsm 18lbs bond min for OMR Barcode paper 120gsm 32lbs bond max Depth of output doc 89mm 3 min 152mm 6 max Hopper capacity Up to 500 sheets of 80gsm 20lbs bond Daily Post Up to 3 sheets C or Z fold or 5 sheets V fold of 80gsm 20lbs bond May be stapled or not but staples on Z fold only Max thickness of staple 2mm Allowable staple posi tions shown below Note all daily post forms must be the same length 140 Operator Manual 61 11 2 Insert Feeder Unit Insert Sizes Single Hopper Depth 76mm 3 min for module 1 89mm 3 min for following modules 152mm 6 max Width 140mm 5 min Widths below 168mm 6 6 require narrow finger kit A3348A 241mm 9 max Thickness 60 gsm 16lbs bond min 4mm 5 32 booklets max Notes Inserts must be flexible enough to suit path contraints Some inserts may require special feed tyres Hopper capacity Up to 300 reply paid envelopes or 150 2mm booklets Insert Sizes Tower Hopper amp OMR Feeder Depth 76mm 3
9. 2 A4 Feed Control Mode Feed always Module 7 Hopper 3 A4 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 Click on Job Name and edit the job name as required either by typing job name 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 Selecting a Click on Configuration and select an existing one from the list if any configuration To create a new configuration see The Configuration Screen on page 29 Logging OCR Click on Log OCR data if you are using an OCR scanner on the output data Late 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 divert 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 co
10. 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 S 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 140 Operator Manual 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 oN 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 t
11. F to ed A control 32111195 Quantity mode Documents Quantity 200 Control Mode Auto restart Ba Configurations Jobs Jog MAp Pause time G Envelopes Envelopes count Q A Users Statistics Engineering Admin OF X Cancel fa sav S Exit 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 140 Operator Manual 35 5 9 7 Setting Ensure that the Postage tab in the configurat
12. 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 12 140 Operator Manual 5 3 The From this screen you run and stop the machine and control the speed Run screen It is also possible to change the selected user change the selected job explained and enter Edit Configuration authorised personnel only Current time Machine Exit to setup and date Select user graphic Select job screen Exit software 4 r 16 10 2008 14 29 45 3 Internal DEFAULTS de E i N a o gt J 4 d4 EEE je J Status Reset count Autoend Run button Output rate Speed control Double Process one Stop button indicator and indicator 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 140 Operator Manual 13 5 3 1 To change the User 5 3 2 To change the Job 14 Users Please select item from list Operator 101 Russell 102 Genstaff_1 103 Gemma P 104 EE Please select item from list Click on
13. any configuration has been deleted from the list box in the Setup screen see page 19 140 Operator Manual 29 30 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 ce 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 ore Yi reads Fluuuer 2 Fead standard jouer ai Head standard hopper a DL PlusPius 121mm Please select and nee pra Seal Mode 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 1 140 Operator Manual 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 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 Documents Please select tem from list Select the required document and click Ok Bn One 3rd Letter fold
14. condizioni della Direttiva Bassa Tensione 2006 95 CE e la seguente direttiva EMC 2004 108 CE ed conforme alle seguenti norme armonizzate s o ad altre specifiche quali EN 60950 1 2003 Revised 7th July 2006 EN 61000 4 3 1996 A1 A2 EN 55022 1998 A1 A2 EN 61000 4 4 1995 A1 A2 EN 55024 1998 A1 A2 EN 61000 4 5 1995 A1 EN 61000 3 2 2000 EN 61000 4 6 1996 A1 EN 61000 3 3 1995 A1 A2 EN 61000 4 11 1994 A1 EN 61000 4 2 1995 A1 A2 Declaraci n CE de Conformidad El producto al que se refiere la presente declaraci n cumple con las condiciones de la Directiva de Baja Tensi n 2006 95 CE y la Directiva los siguientes EMC 2004 108 CE y est en conformidad con las siguientes normas armonizadas s u otras especificaciones EN 60950 1 2003 Revised 7th July 2006 EN 61000 4 3 1996 A1 A2 EN 55022 1998 A1 A2 EN 61000 4 4 1995 A1 A2 EN 55024 1998 A1 A2 EN 61000 4 5 1995 A1 EN 61000 3 2 2000 EN 61000 4 6 1996 A1 EN 61000 3 3 1995 A1 A2 EN 61000 4 11 1994 A1 EN 61000 4 2 1995 A1 A2 70 140 Operator Manual
15. 3 Setting the document options for the Feed unit 31 5 9 4 Setting the feed options for the Feed Unit cccccccncccccccnn co 32 5 9 5 Setting the module options for a Folder ccccececeeeeeeneee 34 5 9 6 Setting the output ODUONG rindas die 35 5 9 7 Setting the postage Options ccccccscesennceeeccesnneeeesseees 36 5 9 8 Setting the miscellaneous optionS ssssssssssrsrsrrnrnrsrsn 37 SAO TNE JOD Slee e n E aa e E Enee 38 Sea The Users SCV CCN PPP 39 140 Operator Manual 10 11 12 5 12 The Statistics SCT Micros 40 2 DO F O a E E E NN 40 JLA ira AA po a A n 41 5 12 3 Current amp PREVIOUS SESSIONS ssssssssssrrrrnrnrsrrrrnrnnnrsns 41 A Bo EE EEE 42 5 12 5 Open Archive A RE ECO O 43 RUANIDNO TNE JOD ss A 4 4 Daily Post Hanadteed sino 45 Setting Up The Machi Brains 46 8 1 Loading the paper hoppers Insert Feeder Single tower OMR jas A sine vearernineuanesouel 46 8 2 Loading the envelope hopper veraces 47 8 3 Setting the separator gap unimarc ii 48 8 4 Using the accumulator ari ciao 48 8 5 Operator settable separator Optional coooocccccrccconcnnanorannnno 49 Operator Maintenance s 25 22220222020u202u200u2ununnnnnn 50 9 1 Clearing paper crasheS sssssssssssssssssssensusnesnssnsnnnnenesrsnenene 50 9 2 Cleaning rollers and sensors sssssesssssssnsnsnnnnsrnnnnnnenesrsnnnene 52 9 3 Maintaining the wetting system s sssssss
16. 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 Warning 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 140 Operator Manual 5 3 4 To adjust c 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 Click on the feeder or folder on the machine graphic to display the fine tuning screen Pins Junie sersa Fine Tuning Module 1 1h Feeder 7 Config Fine Tuning DEFAULTS Feeder of any type No fine tuning of the unit part of the feeder is available Tower Figs Junie sersey Unit Fine Tuning Module 8 3p3h Folder 2 Config Fine Tuning DEFAULTS 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 ca
17. Event Another DCO 280808 10 07 2008 12 10 12 B Machine Stopped 10 07 2008 12 10 14 C Machine Started Event_FixedGroupSize JAB _ 07 10 07 2008 12 10 15 12 null Event FixedGroupSize JAB og 10 07 2008 12 10 16 12 null 10 07 2008 12 10 16 2 null i Event_FixedGroupSize JAB 10 10 07 2008 12 10 17 12 BTDAAAARHARI B fen Fria HONE 21018 p ca Event_FixedGroupSize JAB _ 19 10 07 2008 12 10 19 I2 null 10 07 2008 12 10 19 O BIDAAAAHARI B 10 07 2008 12 10 19 12 BDDAAAAJORN B O B L M K C 12 12 12 12 12 12 12 10 07 2008 12 10 21 BDDAAAAJORN B Machine Stopped JobRun Ended Button Pressed RUN JobRun Started Machine Started null null null null null null null 10 07 2008 12 10 42 10 07 2008 12 10 43 10 07 2008 12 11 23 10 07 2008 12 11 24 10 07 2008 12 11 25 10 07 2008 12 11 26 10 07 2008 12 11 26 10 07 2008 12 11 27 10 07 2008 12 11 27 10 07 2008 12 11 28 10 07 2008 12 11 28 10 07 2008 12 11 29 Oo000 000 0 00 00 00 000000000 aaa sooo gt gt O0D0O0O00N0ONDa gt Bb 2 2 x3 2x x2200000 Points to note E 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 Maxim
18. Label name None Ime None Thickness mm Wetting rate iE Save As Default 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 Click on Name and edit the name as required either by typing it or by the setup using the on screen keyboard Any changes made here will be reflected in name 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 Editing the Icon Select the icon from a preset list this icon that will then appear in the settings 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 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 above will not be active 140 Operator Manual 21 Editing the True Weight This shows the weight of the envelope in the units shown and setting
19. One 3rd Letter folded Please edit avalaible and accessible settings if neccessa Document name Address Position Top Icon wi Form type One 3rd Letter folded a soe Paper Weight gsm xX Width mm Depth mm Pre Folded Leaves Omr name 16 OMR SAMPLE TEMPLATE Label name FOG SAMPLE TEMPLATE Bse Gen 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 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 True Weight below Pre Folded Leaves If the insert consists of more than one leaf eg a z folded fl
20. TABLE OF CONTENTS 1 IN EFOGU CEOND asis ias 3 tek AAA a eo EA G 3 1 2 Notes on the Use of this Handbook 0 ccc cece sees eee e eee eeeeeeees 4 2 Safety NOTES minar 4 2 1 General safety noteS sssssssssssssnenrrrrnrsrrnennrrrunerrrnrnrrrrnnrnne 5 22 Endo C eee A E EA 6 3 Technical Specification sisas 8 4 Macmne LAVOUE GUIA O aislar reinas 9 A leo ei e 9 Az Parts identification se sipcenusachenpendejolcotisi ctoicoec doc je secos ito besoo sees 10 5 Operating INSUFUCTION Sarna 11 SL Wnats ifn this DOCUMEN casonas irekiten eA AAE ENEN 11 5 2 Starting the Operating PrOd PAM aida 12 5 3 The Run screen explalC disorder 13 5 3 1 To change the LCCC arranc 14 5 3 2 TO Change o e O 14 5 3 3 To adjust the Envelope Inserter SettingS cccccecseueueenees 15 5 3 4 To adjust the Document Inserter settings ccccccccnncccncc oo 17 Be Ne Set Screens 19 5 4 1 The Setup screen explained s ssssssrsrsrsrrrrnrsrerrrrnrnrnrsn 19 la Te ISE BOK oerrinne EE ERE bs 20 Swa TNE ONE 06S OTEC rirnan ne n eee toros eos 21 5 6 The Barcode Label SCree n cccccccecceceeceeceueeueeueeueeueeueeueeueeuenneegs 23 5 7 The Documents Screen saisie alcoi 25 5 8 The Envelopes screen s ssssssssessssnsssssennnsnennssnsnnnnenesrsnsnenesse 27 5 9 The Configuration screen nacion ai reina 29 5 9 1 Configuring the inserter servira 29 5 9 2 Setting the inserter options for the Inserter unit 30 5 9
21. abel is accepted Set to low number if print quality is poor 140 Operator Manual 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 label Data logging characters If data logging is being used click on and enter the start character position and number of characters See also page 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 charact
22. above requirements may affect machine performance 140 Operator Manual 11 4 Mechanical amp Electrical Speed Variable up to 4500 3750 for SE versions filled envelopes per hour DL envelope with 1 C fold A4 Noise level 75dbA 3 x feeders 1 x 3 plate folder measured at 1 6m height 1m from nearest cover Heat Output BTU Hour Rated current x rated volts x 3 412 eg 2866 BTU Hour for typical configu ration of 3 x feeders tower folder Heat Output Watts Rated current x rated volts eg 840W for typical configuration of 3 x feed ers tower folder Electrical Frequency Input Current Fuse Rating Insert Head Weights nett Inserter Head Feeder Tower Feeder Tower Folder Feeder Folder Cardfolder 2 DTI 230VAC 50Hz Head 1A Feeder 0 5A OMR Feeder 0 5A Tower Feeder 0 5A Tower Folder 1A Feeder Folder 0 75A T6 3A 56Kg 25Kg 44Kg 70Kg 43Kg 50Kg 25Kg 115VAC 60Hz Head 2A Feeder 1A OMR Feeder 1A Tower Feeder 1A Tower Folder 2A Feeder Folder 1 5A T10A 3 tray version including 15Kg accumulator 140 Operator Manual 65 Ambient light Although the machine may operate in sunlight it is not designed for use in direct sunlight or where sunlight is exposed to the machine through windows or skylights The light sensi tive sensors can be affected in these conditions It is therefore recommended to a Locate the machine out of direct sun
23. ailer Plus Data DataLogs For full details of analysing Data Logs see document Data Log Specification 140 Operator Manual 5 12 5 Open Archive 140 Operator Manual Select Open Archive on the Statistics Diagnostics screen to display the details of archives selected by date Archives are automatically created for each session and are saved on the computer until the end of the current month At the end of the month all session archives are collected into one archive and named as that month and the year For example on the first day of June all session archives for April will be available in a single archive named Apr followed by the year All data up until the end of the month can be seen from the main Statistics screen by pressing Show events data as previously described Archives are stored on the PC of the machine at C Program Files Pfe Maximailer Plus Data Archives DB gt Monthly archives are shown see text below for archive format Select from list Daily Archives Faulty Archives Select from list Apr_2008 Jul_2008 Jun_2008 May 2008 Monthly Archives All Other Archives All Archives Y 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 bu
24. al rollers and other document feeding aids exist which can often accommo date problem stationery that other inserter folders may not be able to These can be ad vised upon by the Technical Support department 140 Operator Manual 99 11 1 Form Sizes Tower Folder 60 Depth Width Thickness Depth of output doc Hopper capacity Collation pocket Folding capacity Daily Post 140mm 5 min 406mm 16 max 140mm 5 min Widths below 168mm 6 6 require narrow finger kit A3348A 229mm 9 max 60gsm 16lbs bond min 70gsm 18lbs bond min for OMR Barcode paper 120gsm 32lbs bond max 89mm 3 min 152mm 6 max Up to 500 sheets of 80gsm for tray 1 top tray Up to 250 sheets 80gsm for trays 2 amp 3 Capacity for up to 8 sheets of 80gsm 20lbs bond before folding or up to 10 sheets of 80gsm 20lbs bond for diverting Up to 8 sheets of 80gsm 20lbs bond folded together C Zor V fold up to 4 sheets of 80gsm 20lbs bond for double forward fold Note that this is dependent upon stationery type and weight and may impact on machine performance Up to 8 sheets of 80gsm 20lbs bond for C Z or V fold up to 4 sheets of 80gsm 20lbs bond for double forward fold May be stapled or not Max thickness of staple 3mm Allowable staple positions are shown below No staples in area shown JAPE gt _ IRECTION n i
25. anual Cleaning sensors contd Insert and collate area For all positions shown direct the jet of air onto the sensors indicated by arrows in the following views Note that sensors are in two halves receiver amp transmitter both halves must be cleaned Open the perspex cover and front feeder x LD cover then lift the front most green H COLLATE POCKET UPPER A handle to raise the mechanism this is held in the raised position by a latch COLLATE INPUT UPP COLLATE POCKET LOWER o COLLATE NPUT LOWER O O O HOPPER LOADED J For the sensor pairs liberally spray the air jet in the gap between them DESKEW 2 O a NVELOPE INSERT NVELOPE WIDTH Feeders TRACK a e A o HP UPPER Lower the feeder side cover and d Fo raise the top cover Swing the EC KEW A al Fuad upwards to raise the E roller platten O DD LOWER To p o lt 0 Note station 1 feeder is shown others are similar HP LOWER COLLAIT NT RY ON POSTS Q
26. ated with a Job Click on Job in the Setup screen and select the configuration as described in the The Job Screen on page 38 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 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 140 Operator Manual 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 140 Series General Specifications 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 Icon E 2 Form type Handfeed D Width mm 210 W Depth mm 297 D Paper Weight gsm 80 Omr nam Computed iv 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
27. ator Internal Job Run Efficiency 2 6 Machine Efficiency 100 0 19 09 2008 18 0 First Run Started 17 10 2008 14 55 18 Filled Envelopes per Postage Groups Last Run Finished 17 10 2008 14 56 34 7 19 09 2008 Number of Runs 1 24 09 2008 Job Run Time 00 01 16 Setting Downtime 00 01 14 24 09 2008 Total ti 00 01 14 Dperator Dover 00 00 00 System Running 00 00 02 Error Downtime lt 5 min 00 00 00 24 09 2008 A Run Speed 6 Excess Downtime gt 5 min 00 00 00 24 09 2008 A Operator Stops Operator Errors 16 10 2008 OMR Barcode Warnings 16 10 2008 Machine Errors Total Stops 16 10 2008 16 10 2008 16 10 2008 16 10 2008 16 10 2008 17 10 2008 17 10 2008 Select All Head Faults Module Faults 2000000000 o 2000000000 seocoecocoe COIN oimeoc9cewmeoo eee 2socoooeqo eae o 200000000 o ein 2000000000 ojn 2000000000500 v Select an event and press OK to view the summary as shown above Note that you can also select more than one event by selecting the first in a range holding down the shift key and then selecting the last in the range Alternatively all events can be selected by pressing the Select All button If a printer is connected the summary can be printed by pressing the Print button The data will be collated and printed in portrait format Press the Current button to view only the events that have occurred since last logging on The Previous button sho
28. by authorized Service Agents Operating Never reach into the machine when it is running This could only occur if a safety 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 Cleaning Prior to cleaning the exterior of the machine it should be disconnected from the the power supply When cleaning the machine do not use liquid or spray machine cleaners but only a cloth dampened with water Cleaning When cleaning sensors use only non flammable airdusters eg part number sensors EOO70A Other types may use flammable propellants which could result in fire or explosion 140 Operator Manual 5 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 o When the device does not function properly in spite of Agent following the instructions provided o 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
29. ce within a Group Incrementing iS Save gt 4 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 Click on Barcode name and edit the name as required either by typing it or the setup by using the on screen keyboard Any changes made here will be reflected in name the Barcode list box when the Barcode screen is saved and exited Editing the The buttons below Name relate to label settings and other non BCS character settings functions These are briefly described below for non BCS characters Number of characters in label Up to max 25 for BCS system Definition mode Only As printed is available 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 Technical 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 l
30. ched off e Mode C the belt moves continuously With the the turning knob it is possible to set the interval distance between envelopes on the conveyor belt The distance depends on the type of job and preference of the user Minimum interval distance 15mm setting for a job with thin envelopes O Neutral interval distance 20mm Maximum interval distance 40mm setting for a job with thick envelopes 68 140 Operator Manual neopost EC Declaration of Conformity According to Annex lll B of the Low Voltage Directive Manufactured by Neopost Technologies Limited Oakwood Hill Industrial Estate Oakwood Hill Loughton Essex 1610 3TZ Herewith declares that the Product DS 140 Product description Feeder folder mail inserter First Year of the CE Marking 2004 Which this declaration refers to is in accordance with the conditions of the Low Voltage Directive 2006 95 EC And the following Directive EMC 2004 108 EC And is in conformity with the following harmonised standard s or other such specifications EN 60950 1 2003 Revised 7th July 2006 EN 61000 4 3 1996 Al A2 EN 55022 1998 Al A2 EN 61000 4 4 1995 A1 A2 EN 55024 1998 Al A2 EN 61000 4 5 1995 A1 EN 61000 3 2 2000 EN 61000 4 6 1996 A1 EN 61000 3 3 1995 A1 A2 EN 61000 4 11 1994 A1 EN 61000 4 2 1995 A1 A2 Authorised on Behalf of Neopost Technologies Limited UK Name Simon George Position Site Direct
31. chine functions Click on this to take you back to the Run Screen 19 5 4 2 The List Box Letter 102 DL Card 99mm 103 C5 149mm 104 Cheque 105 9 BRE 107 One 3rd Letter folded 108 Half Fold Letter 106 A5 Insert 109 Jan_draft_A4 110 Jan_draft_ltr 111 Insert 135 112 Insert 160 113 Find Name Documents Currently selected Insert 160 113 ForminsertiD 113 Paper Weight gsm 160 Icon 13 Thickness mm 0 22 True Weight g 3 33 ComputedThickness Yes Computed Yes Omr name None Label name Hone Pre Folded Leaves 1 Address Position Top Doc ID mode Off Doc ID Click on any of the buttons on the Setup screen to display a list box Shown left is the list box for the Document and is similar for all of the buttons on the Setup screen The list box shows all of the setups that have been defined so far Select any of the setups shown and this can then be edited copied or deleted by clicking on the appropriate button at the bottom of the box New setups can also be created by clicking on the New button and the newly created item can then be edited as required Note that each name is allocated an ID number by the software this being 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 ap
32. cted to Live Line CAUTION This machine is supplied with an unterminated mains cable for hard CAUTION wiring or connection with a suitable 16A plug socket conforming to IEC 60309 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 Input Voltage Input current Model Name 140 series Model Number 1430 230 Volts 0 50 Hz 115 Volts O 60 Hz 3 5 Amps 7 Amps Sound Reading 75dBA 75dBA measured 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 140 Operator Manual 4 MACHINE LAYOUT GUIDE 4 1 Description of machine The function of the machine is to feed forms from a number of hoppers fold them in either Cc 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 c
33. dbook 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 operated 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 o an electrical shock o injuries from the intake at the rotating rollers o damage to the machine IMPORTANT To switch the machine off in an emergency open any cover 4 140 Operator Manual 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 Important The machine must be installed only by an Authorised the Service Engineer A safe level position is necessary when installing the machine 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 t
34. e 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 34 140 Operator Manual 5 9 6 Setting the output options CE This option is only available if a conveyor is fitted CS 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 set up batching on the output conveyor where fitted Note This screen will only be available to personnel with Supervisor access Configuration DEFAULTS Je
35. ed Insert 135 gt 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 19 140 Operator Manual 31 5 9 4 Setting the feed options for the Feed unit CS Note that the options in the dialog box may vary from those shown depending on whether the unit is a feeder or a folder Mark Reading E Select Save as Default to make this the default a id ead for all new setups These Cascading Mot cascaded settings then apply to Load Default 32 Click on the lower icon of the numbered feed unit showing the unit icon and the following dialog box appears module 12 readers rloguer 12 Module studard Hover Module standard hopper Please select and modify settings Address carrier Ho Feed Control Mode Feed always Form Count Thickness doubles Deskew Item Id 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 Always 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
36. el to remove grouped 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 48 140 Operator Manual 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 necessary 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 20lbs 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 o
37. er 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 confirmation of envelope contents After making any changes click the Save button at the bottom of the screen and then the Exit button to return to the list box 140 Operator Manual 37 5 10 The Job screen Job DEFAULTS Please edit avalaible and accessible settings if neccessa Current settings Job name Module 0 Hopper 1 DL PlusPlus 121mm Seal Mode Always DEFAULTS Module 1 Hopper 1 DL Card 99mm Feed Control Mode Feed always Configuration 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 Late divert 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
38. er 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 Job 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 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 24 140 Operator Manual 5 7 The Documents screen C Document
39. flap to seal before the Y OOOO O envelope is ejected XK Abort wW Do It 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 complete click on the Unit button for hopper settings as described opposite Important All fine adustments apply only to the current job and will not affect any other jobs 140 Operator Manual 15 Fins Janina seraa 16 Unit Fine Tuning Module 0 Hopper 1 7 Contig Fine Tuning DEFAULTS Y Hardware Fine Tuning Document Fine Tuning DL PlusPlus 121mm Hopper Fine Tuning From here you can adjust hopper settings Click on the inserter hopper then
40. he head end C Closer area at the head end Ensure the machine is switched off before cleaning rollers or sensors To access rollers in the insert area raise the perspex cover and lift the green handles to reach the paper path Rotate rollers by hand when cleaning To access feeder rollers lower the LH side cover and lift the infill cover in front of the hopper Use the green knob to rotate the rollers for cleaning Note after a long period of time some inserts can cause a jam with the insert stuck between the rollers this may especially occur on coated material If this happens open the upper roller plate with the green latch and using a cloth dampened with Roller 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 52 140 Operator M
41. he 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 Electrical The machine may only be connected to a voltage of 230V 50Hz or 115V 60 danger Hz depending upon model The mains plug may only be connected with a socket having an installed protective contact The protective effect will be compromised 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
42. he 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 c 1 Tower folder is shown feeder folder is similar except only 1 tray is fitted and there is no indicator 2 See the following page for setting the curled forms stop 140 Operator Manual 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
43. if neccessa Output Postage Metering Miscellaneous DEFAULTS 3 4 2h Feeder 2p1h Folder DL Card 99mm DL Card 99mm Hopper 1 Hopper 1 Hopper 2 Hopper 1 3p1h Folder Hopper 1 Hopper 1 i Save As Default 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 Hopper 2 Hopper 1 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 than 6 stations use the scroll arrows to move sideways Pome Us rlud louver hi raad standard uu nes Enis Please select item from list Select the required envelope and click Ok E Note An error will occur if an envelope that is used in
44. ine Stopped 350 Envelope Separator Area blocked 0 204 5 FixedGroupSize JAB Internal Machine Stopped 350 Envelope Separator Area blocked 0 204 5 FixedGroupSize JAB Internal Machine Stopped 355 Jam at envelope Separator Area D 204 5 Touch the TE FixedGroupSize JAB Internal Stopped by Dperator 0 0 204 5 FixedGroupSize JAB Internal Machine Started 0 0 202 5 FixedGroupSize JAB Internal Button Press 1 Covers open D 202 5 Touch the FisedGroupSize JAB Internal Machine Stopped 451 Jam at Insertion Wetter Area 0 202 5 FixedGroupSize JAB Internal Stopped by Operator 0 0 202 5 FixedGroupSize JAB Internal Machine Started 0 0 196 5 FixedGroupSize JAB Internal Job Started 0 0 196 5 FixedGroupSize JAB Internal Button Press 1 Covers open 0 196 5 FizedGroupSize JAB Internal Job Ended 0 0 196 5 FizedGroupSize JAB Internal Machine Stopped 451 Jam at Insertion Wetter Area 0 196 5 FizedGroupSize JAB Internal Stopped by Operator D D 196 5 FixedGroupSize JAB Internal Machine Started D D 182 5 02 05 2008 11 09 35 FizedGroupSize JAB Internal Button Press 1 Covers open D 182 5 3 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 43 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 12 1 Filter 40 Press the Filter button and set
45. ion screen is selected the postage This section allows you to define weight groups for setting different options c Select Save as Default to make this the default for all new postage setups Setting the weight group thres holds Setting the postage rates 36 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 7mos Ba Configuration DEFAULTS i Please edit avalaible and accessible settings if neccessary Units Output p a e Miscellaneous El OMR Codes FAA Weight Group Thresholds Postages and Metering Options Group 1 of Weight g 0 00 JOE Postage Barcodes Label Envelopes Group 2 of Weight g 0 00 HOR Postage Documents Configurations Group 3 E Jobs of weight a 0 00 BE Postage uu SOE Postage Admin El a save 6 exit There are four weight groups each one defining a range with a lower and upper weight and a postage rate to be set for that range The upper weight that you set for each group will automatically appear as the lower weight for the following group enabling an ascending scale of postage rates to be set for the four groups To set the threshold for the first group click the Weight Group 1 button and en
46. ionery 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 1 Mintmum document width tn the pack including inserts must be no smaller than the maximum document width by more than the following Minimum document width Maximum document width 2 58mm eg if maximum document 210mm minimum document width 210 2 58 163mm minimum 26 140 Operator Manual 5 8 The Envelopes screen Envelope Untitled Envelope1 Untitled Envelope1 Width mm Depth mm Paper Weight gsm Flap mm Computed iv
47. light b Protect the machine from direct sunlight using blinds or similar blocking devices If the machine can only be located where it may be exposed to direct sunlight then please contact Technical Support department who may be able to advise on the use of blocking material on the inside of the Perspex cover where necessary 66 140 Operator Manual 11 5 Machine Dimensions DO t Wd C3 a PJ i oF 9 AAA AA a a a o O O E ME E E E TE E E E O gt i o E l l l l E 5 NL Notes 1 Allow minimum 1 metre working space on the operator side and output end Allow minimum 150mm from non operator side of machine to adjacent wall Allow sufficient space at paper trays to enable comfortable loading and access for tray removal 2 If moving the machine ensure the wheel brakes are off and push on the stand not the machine The machine must be moved on a smooth surface only 3 All dimensions are in mm 140 Operator Manual 67 12 HIGH CAPACITY CONVEYOR BELT CS 2 Optional The high capacity conveyor belt is designed for envelope transport from the inserter or franking device The conveyor belt has two operation modes e The belt moves continuously e The belt moves in intervals The belt moves each time a sensor detects the passage of an envelope Operating the High Capacity Conveyor Belt The conveyor belt switch has three position e Mode A the belt moves in intervals e Mode B the belt is swit
48. ly 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 for a dialog box appears Folder orate E 3190 Folder 3p3h Folder Please select and modify settings ul Fold Type Feed orientation Document orientation Feet first Fold Plate Lengths mm F1 97 0 F2 0 0 F3 102 0 Folded Length mm Address adjust mm gt Select Save as sinatra Default to make this the default for all new setups These settings then apply to Load Default a oss oae Address position Options are Top Middle Bottom Will apply to the hopper with the address carrying document Not
49. n also be adjusted in Module Settings in the Configuration screen see page 34 Whichever was adjusted last will take precedence Hardware Fine Tuning y Document Fine Tuning Important All fine adjustments apply only to the current job and will not affect any other jobs 140 Operator Manual 17 Fine Ponny ser Config Fine Tuning DEFAULTS Feed Control Mode Doubles Detect Off Off On Deskew Low Feed always A 0 00 0 75mm Separator Position Document Fine Tuning DL Card 39mm Depth mm 99 Width mm 210 Fine Tuning Module Hopper 1 El 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 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
50. n where applicable Note that for Daily Post only configurations in table 1 column B can be used Fold generation requires Foldplate 1 set to 1 3rd paper length Foldplate 3 set to 1 3rd paper length Table 1 a wom i ees VE ee Z LL ome as a 6 a a ORT LiL Beep 331 TE 2 ga EE fo BSE b E Preferred fold configurations are indicated bold and give correct address orientation in window of standard envelopes Shaded areas denote folds that give ncorrect 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 140 Operator Manual lable 2 FEED TRAY LOADING WHEN ACCUMULATION TRAY FED TRAY LOADING WHEN IS NOT IN USE CCUMULATION TRAY IS USED FORM ORIENTATION FEED FORM ORIENTATION OMR READ ON FEED TRAY SEQUENCE ON FEED TRAY EAD POSITION
51. n the paper as it is withdrawn rearwards Refit the infeed plate and trays f knob to achieve the z A weil required setting see k Pres above a Turn the adjusting 6 CR Note separator is shown with black inner cover not fitted 140 Operator Manual 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 the top perspex cover and small feeder cover Lift the green latch bars as shown to access the paper paths below Carefully a LOA ae eA withdraw any jammed paper N YES As taking care not to tear it To clear POSO th im RE y a crash in the feeder lower the Ola feeder side cover and swing the green handles upwards to access the paper paths If necessary use the green knob to turn the shafts for winding out jammed paper If a jam occurs at the input of the envelope or feeder hoppers remove all material and withdraw the jammed item For feeders ensure that the 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
52. njunction with ID field label Checking Not currently used 38 140 Operator Manual 5 11 The Users screen User Gemima Please edit avalaible and accessible settings if neccessa User name ease Operator Supervisor Engineer Admin Special Superuser RunScreenShow RunScreenStandard RunScreenAll FineTuningDocShow FineTuningDocStandard FineTuningDocAll 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 rdles 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
53. ode 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 OMR Code Barcodes Labels Documents Envelopes Configuration Job Users Statistics Engineering Admin Run Screen 140 Operator Manual Allows OMR mark settings to be created viewed or altered Allows Bar Code settings to be created viewed or altered Allows form and insert settings to be defined or altered Allows envelope settings to be defined or altered Configure the machine for all settings to use with the selected stationery Create a new job or alter an existing one Allows a new user to be added and a password and permissions to be set These can be also be altered for existing operators Displays information on current machine settings production run data etc Allows testing of various parts of the machine Only available to personnel with engineer access and described in detail in the machine Service Manual Allows administration of various ma
54. ok carefully so that the information it contains may be available at all times 1 1 Pictograms N General Warnings N Warning of danger from electricity or electrical shock cS Information Note indicating important information regarding the handling of the machine 140 Operator Manual 3 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 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 han
55. ollated 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 ordered 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 tray
56. or Date December 2004 140 Operator Manual 69 Part Number K6 0136 A D claration de Conformit CE Ceci est une copie d un document original qui est la propri t de Neopost Technologies Ltd Le produit auquel se rapporte cette d claration est conforme aux conditions de la Directive Basse Tension 2006 95 CE et la directive suivante CEM 2004 108 CE et est conforme a la norme harmonis e suivante s ou d autres sp cifications EN 60950 1 2003 Revised 7th July 2006 EN 55022 1998 A1 A2 EN 55024 1998 A1 A2 EN 61000 3 2 2000 EN 61000 3 3 1995 A1 A2 EN 61000 4 2 1995 A1 A2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 1996 A1 A2 1995 A1 A2 1995 A1 1996 A1 EN 61000 4 11 1994 Ai EG Konformit tserkl rung Das Produkt auf das sich diese Erkl rung bezieht in bereinstimmung mit den Bedingungen der Niederspannungsrichtlinie 2006 95 EG und die folgende Richtlinie EMV 2004 108 EG und steht im Einklang mit der folgenden harmonisierten Norm en oder sonstigen Angaben EN 60950 1 2003 Revised 7th July 2006 EN 55022 1998 A1 A2 EN 55024 1998 A1 A2 EN 61000 3 2 2000 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 1996 A1 A2 1995 A1 A2 1995 A1 1996 A1 EN 61000 3 3 1995 A1 A2 EN 61000 4 2 1995 A1 A2 EN 61000 4 11 1994 Ai Dichiarazione CE di Conformit Il prodotto al quale questa dichiarazione si riferisce conforme alle
57. ostly applies to legacy jobs 140 Operator Manual 21 Also set the Pitch Gate position from Top of Form Leading 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 SICK 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 22 140 Operator Manual 5 6 The Barcode Label screen asw Barcode Wk 44_2 Please edit avalaible and accessible settings if neccessary Barcode name Wk 44 2 Character Function Label machine control Standard BCS Control A ee ra Form Sequence within a Job Symbology Default Form Sequence within a Group Grouping End of Group Security check Data log enabled Divert oversize group Divert blank sheet Data logging characters Customer ID characters Form Sequence within a Job Incrementing septal usc s Form Sequen
58. paper out if raising the roller carrier at the exit An easier method is described below ol 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 50 140 Operator Manual Tower Unit Open the side cover and operate the 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 140 Operator Manual 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 t
59. plied to list only names or IDs containing 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 List Box OMR Code Barcode Labels Documents Envelopes Configuration Job Users Page 21 Page 23 Page 25 Page 27 Page 29 Page 38 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 20 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 29 140 Operator Manual 5 5 The OMR Code screen OMR Wk 44_1 Please edit avalaible and accessible settings if neccessary OMR name Definition mode Code type Number of marks Gate position Parity Security count direction Security count start Pitch Gate position mm Leading margin mm Trailing margin mm Di
60. 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 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 injudicio
61. s 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 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 140 Operator Manual 5 9 The Configuration screen Configuration DEFAULTS Please edit avalaible and accessible settings
62. s 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 symbologies 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 140 Operator Manual 9 4 2 Parts identification Daily post tray PC control panel Tower feeder Tower folder see below
63. ssssssssrrrrnrsrererrnenrnrsns 56 Document Orientation TableS sssss 2 57 General Specifications ss 2 2 59 LEL POR ZO sinusal EE ita aa E 60 ILZ Inon E Cder Wil eon enr o Aae EEEREN EREA 62 11 3 Envelope Specification sssssssssessnssesesnnnnenrrnenrrnennrrrnnerern 63 11 4 Mechanical Electrical sssr dden en a TEA 65 11 5 Machine DimenSioOnS sssssssssssssnsrrnnsrrnnsnrnnsnrnnnnrnnnnrsrennerena 67 High Capacity Conveyor Belt CS 2 Optional ssssss222 68 140 Operator Manual 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 handbo
64. ter the upper weight of the range in grams Press Enter To set the postage rate for Group 1 click the Postage button and enter the rate for that group Press Enter Repeat the above steps for the remaining groups if required Note The weight of the filled envelope is determined by the weight of each inserted document and the envelope These are set in the Document and Envelope options in the Setup screen see pages 25 amp 27 140 Operator Manual 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 E OMR Codes Miscellaneous options Configurations DEFAULTS Main Jdatalyysyinyg unit w EEEE P Main datalogging unit Prime Unit Please select item from list Address carrier Module 8 Hopper 1 Confirm Calibration Ho MPPC settings Documents Control mode n CI Envelopes Configurations Module 4 Se Jobs Module 6 Module 8 Statistics Engineering B Admin 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 furth
65. 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 Job button to view the list of jobs To change to a different job click on the name and you will see the new job name at the top of the Run screen To create a new job The Setup Screen must be entered see page 19 140 Operator Manual 5 3 3 To adjust Note Click on the Unit button in the top left corner the Envelope to toggle between fine tuning for unit and hopper Inserter settings Unit Fine Tuning i z Click on the envelope Fine ine serasi i inserter on the machine ot PC graphic to display the fine tuning screen Click on Hardware Fine Tuning to Collate Pkt Adj 0 1mm i Ea display dial information Fingers Adj 0 1mm 0 mi You can select alo hi Ll a The width of the collate S EEA ce pocket guides Adjust wetter stop mm 0 Adjust env seal pos mm 0 b The overall width of the Adjust envelope stop mm 0 insert fin gers Insert in env position mm 0 c The time allowed for Adjust env reverse pos mm Ll i ESES the
66. 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 ill Select Records Filter Custom C Month l Daily Today 00 00 00 i 00 00 00 End Date 00 00 00 End Time 00 00 00 All Dates Job Operator Clear Filter Default X Cancel When the required criteria have been set select OK Press the Show event data button for a list of events similar to that shown in the Event Data screen above Note that the button toggles between show and hide You can also view a summary of this information as described on the following page 140 Operator Manual 5 12 2 View Summary 5 12 3 Current amp Previous sessions 140 Operator Manual Press the Summary button to view the filtered data Note that only valid events will be shown e 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 17 09 2008 13 STATISTICS SUMMARY 17 09 2008 17 Job Name DualTrackTest Documents Fed per Module Filled Envelopes 0 19 09 2008 18 Job Date 17 10 2008 odule cs Production Output 0 per hour Production Rate 0 per hour Configuration DualTrackTest 19 09 2008 18 Oper
67. the list box 140 Operator Manual 39 5 12 The Statistics screen mos OMR Codes A Barcodes Labels Documents Envelopes A Configurations Jobs f users E statistics Engineering Admin CON Description of Button Functions Touch the OMR Code button to view all current OMR settings Statistics Diagnostics Current Session Period Custom Grouping Filter Lasti Prey Sessions Das e Last operator End Date End time Internal Last Doc count Last date time Open Arch p ainis jog Hide event data 4745 17 10 2008 14 56 34 Dperator E ummary Touch the Touch the Touch the Touch the Dperator Name Module Doc Count Speed FixedGroupSize JAB Machine Stopped Wetter tank low FixedGroupSize JAB Internal Configuration Change 0 0 204 5 Touch the FixedGroupSize JAB Internal Machine Stopped 456 Wetter tank low 0 204 5 FixedGroupSize JAB Internal Configuration Change D D 204 5 FixedGroupSize JAB Internal Machine Stopped 456 Wetter tank low 0 204 5 FizedGroupSize JAB Internal Configuration Change D 0 204 5 Touch the FixedGroupSize JAB Internal Machine Stopped 660 Module 3 not responding 0 0 5 FixedGroupSize JAB Internal Button Press 2 Top Cover Open 0 204 5 FixedGroupSize JAB Internal Button Press 2 Top Cover Open 0 204 5 Touch the 02 05 2008 11 19 02 FixedGroupSize JAB Internal Job Ended 0 0 204 5 02 05 2008 11 18 49 FixedGroupSize JAB Internal Mach
68. 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 18 140 Operator Manual 5 4 The Setup screen 5 4 1 The Setup screen explained 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 El on the Run screen ER ios Version o J o f J OMR Codes Barcodes Label Envelopes mm Documents Configurations b 2 2 Engineering Description of Button Functions Touch the OMR button to view all current OMR settings Touch the Barc
69. tton 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 Archives provides access to all of the above shown in one list 43 6 RUNNING THE JOB E 4 CAS pisos Version 0 0 7 mos OMR Codes Barcodes Label Envelopes D Documents Configurations ala I Jobs Users Statistics it Engineering E Admin gt 4 Run Screen Using the configuration Running the Job 44 Description of Button Functions gt Permissions Touch the OMR button to view all current OMR settings Roles 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 Machine ID 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 Now that you have finished defining a configuration it can be associ
70. 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 56 140 Operator Manual 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 Example A IS Fold Chosen is top address C fold 1 Select configuration from table 1 Note column A unshaded 2 OMR or Barcode If NO use table 2 If YES use table 3 for OMR table 4 for Barcode Daily Post table 5 is not an option for this fold type See following page for tables 2 5 3 For chosen table use row A from step 1 This indicates orientation feed sequence and read head positio
71. 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 On line To provide assistance through the various operating screens there will always Help be a symbol available Click on this to display a popup box detailing further information for the area of the software you are using 140 Operator Manual 11 5 2 Starting When you first start the operating 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 q E eo 1611012008 14 29 45 de a 00000000 MOs Usar Logos Status Operator 101 Russell 102 TETT Eea ea eae alee elas la dla Note
72. us handling or disposing of on or into land water or air would represent a major threat to the environment and human health 6 140 Operator Manual 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 Equipment produced after August 13 2005 Not only are you by law not allowed to dispose of the waste equipment via other waste 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 140 Operator Manual T TECHNICAL SPECIFICATION CAUTION CAUTION CAUTION In order to ensure correct safety and operation this machine must only be installed and maintained by an authorized Service Engineer Should any cover or safety interlock be damaged the machine must not be used until service repairs have been completed 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 conne
73. vert oversize group Divert blank sheet Address on every page Wk 44 1 As printed 1 track i Save gt 4 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 Click on OMR Name and edit the name as required either by typing it or by the setup using the on screen keyboard Any changes made here will be reflected in the name OMR Code list box when the OMR screen is saved and exited Warning Do Editing the settings 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 O 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 whichever 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 m
74. 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 140 Operator Manual 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 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 gt 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 chann
75. ws 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 12 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 Logs Select from list Postages Data Logs All Other Data Logs All Data Logs Event_A job DCO _100708 Event_A job DCO _110708 Event_A job DCO _ 140708 Event_A job DCO _220808 Event_Another DCO_020908 ail Event_A job DCO _100708 txt Event_Another DCO_030908 Event Data Log file for Job A job DCO Event_Another DCO_040908 Event Another DCO 050908 Date Time Event Dest Event Data Event_Another DCO_080908 10 07 2008 12 10 06 M Button Pressed RUN 10 07 2008 12 10 08 K JobRun Started Event_Another DCO_270808 1007 2008 12 10 09 C Machine Started
76. yer 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 140 Operator Manual 25 Editing the True Weight This shows the weight of the document or insert in the units settings contd Notes shown and is linked to Thickness above To enter a known weight click the Computed button to uncheck the box and then click the True Weight button Enter the required figure in the units shown Note 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 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 ID Optional Feature Used to verify that the correct stat

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