Neopost DS-140 Operator's Manual
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Neopost DS-140 Operator's Manual

Neopost DS-140 Operator's Manual

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Table Of COnTenTs

1
Introduction ............................................................................... 3
1.1
1.2
2.
safety notes ............................................................................... 4
2.1
2.2
3.
TeCHnICal sPeCIfICaTIOn ....................................................... 8
3.1
4.
Machine layout Guide ................................................................. 9
4.1
4.2 Parts identification ................................................................10
5.
Operating Instructions.............................................................. 11
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9 The Configuration screen .......................................................29
5.10 The Job screen .....................................................................38
5.11 The Users screen ..................................................................39
5.12 The Statistics screen .............................................................40
140 Operator Manual
Pictograms ........................................................................... 3
Notes on the Use of this Handbook .......................................... 4
General safety notes .............................................................. 5
End of Life ............................................................................ 6
Machine rating sheet .............................................................. 8
Description of machine ........................................................... 9
What's in this Document ........................................................11
Starting the Operating Program ..............................................12
The Run screen explained ......................................................13
5.3.1 To change the User .......................................................14
5.3.2 To change the Job ........................................................14
The Setup screen .................................................................19
5.4.1 The Setup screen explained ...........................................19
5.4.2 The List Box ................................................................20
The OMR Code screen ...........................................................21
The Barcode/Labels screen ....................................................23
The Documents screen ..........................................................25
The Envelopes screen ...........................................................27
5.9.1
Configuring the inserter. ............................................29
5.9.5 Setting the module options for a Folder ...........................34
5.9.6 Setting the output options .............................................35
5.9.7 Setting the postage options ...........................................36
5.9.8 Setting the miscellaneous options ...................................37
5.12.1 Filter ........................................................................40
5.12.2 View Summary ..........................................................41
5.12.3 Current & Previous sessions .........................................41
1

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  • Page 1: Table Of Contents

    Table Of COnTenTs Introduction ................3 Pictograms ................3 Notes on the Use of this Handbook .......... 4 safety notes ................4 General safety notes .............. 5 End of Life ................6 TeCHnICal sPeCIfICaTIOn ............8 Machine rating sheet .............. 8 Machine layout Guide ..............
  • Page 2 5.12.4 Data Logs ..............42 5.12.5 Open Archive .............43 Running The Job ............... 44 Daily Post (Handfeed) ............... 45 setting Up The Machine ............46 Loading the paper hoppers Insert Feeder (Single, tower, OMR/ Barcode) ................46 Loading the envelope hopper ..........47 Setting the separator gap ............48 Using the accumulator ............48 Operator settable separator (Optional) ........49...

  • Page 3: Introduction

    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.

  • Page 4: Notes On The Use Of This Handbook

    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.

  • Page 5: General Safety Notes

    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. Important! The machine must be installed only by an authorised Installing service engineer. A safe, level position is necessary, when installing the machine, with sufficient space all round to operate it. The machine is to be machine protected from moisture.

  • Page 6: End Of Life

    In the following cases, the mains plug must be unplugged and the device allow left for the authorized Service Agents: machine to • When the mains cable or plug is worn or damaged. be checked by the • When water or other liquid has entered the device. • When the device does not function properly, in spite of service following the instructions provided. agent • When the device has fallen down or the housing is damaged.
  • Page 7 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.

  • Page 8: Technical Specification

    TeCHnICal sPeCIfICaTIOn Machine rating sheet CAUTION: In order to ensure correct safety and operation, this machine must only be installed and maintained by an authorized Service Engineer. CAUTION: Should any cover or safety interlock be damaged, the machine must not be used until service repairs have been completed. CAUTION: This machine must be earthed.

  • Page 9: Machine Layout Guide

    MaCHIne layOUT GUIDe Description of machine The function of the machine is to feed forms from a number of hoppers, fold them in either ‘C’, ‘Z’, ‘V’ or double forward fold and insert them into an envelope which is then sealed and ejected. Further form(s) may optionally be collated with the first form, either by folding together or collating on the track.

  • Page 10: Parts Identification

    4.2 Parts identification Daily post tray PC control panel Tower feeder Tower folder Standard feeder (see below) Insert/collate area Envelope hopper Note: Station 1 is the first 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)

  • Page 11: Operating Instructions

    OPeRaTInG InsTRUCTIOns These Operating Instructions guide you through the stages of using the machine. The machine is entirely software controlled, with all operator What’s functions being performed on the touch-sensitive control screen. in this 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.

  • Page 12: Starting The Operating Program

    starting When you first start the operating program, you will be presented with the Run Screen, shown below and described in detail on the the Operating following page. The program will start with the last used operator and Program 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).

  • Page 13: The Run Screen Explained

    From this screen, you run and stop the machine and control the speed. It is also possible to change the selected user, change the selected job Run screen and enter Edit Configuration (authorised personnel only). explained Exit to setup Current time Machine Exit software Select user Select job screen and date...

  • Page 14: To Change The User

    5.3.1 To Click on the select User in the logon box to view the list of user. To change change the to a different user, click on the name User and enter the password - you cannot change the user unless you know their password (note that the password is case-sensitive).

  • Page 15: To Adjust The Envelope Inserter Settings

    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 Click on the envelope inserter on the machine graphic to display the fine tuning screen. Click on Hardware fine Tuning to display further information.
  • Page 16 Hopper fine Tuning From here you can adjust hopper settings. Click on the inserter hopper, then Document fine Tuning to display further information. You can select: a: Whether or not the envelope is sealed. Select ‘Off’ if, for example, later hand insertion of an insert or other item will be required.

  • Page 17: To Adjust The Document Inserter Settings

    5.3.4 To adjust Note: Click on the ‘Unit’ button in the top the Document left corner to toggle between fine tuning for Inserter unit(shown here) and hopper (shown overleaf). The settings available will vary between feeders settings and folders. Click on the feeder or folder on the machine graphic to display the fine tuning screen.
  • Page 18 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.

  • Page 19: The Setup Screen

    The setup screen 5.4.1 The From this screen, you make changes to the machine setup. Changes can then be saved and will remain until they are changed again. To setup screen enter the screen, click the setup button on the Run screen. explained Allows OMR mark settings to be created, viewed or altered.

  • Page 20: The List Box

    5.4.2 The list box 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.

  • Page 21: The Omr Code Screen

    5.5 The OMR Code screen 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. Click on OMR name and edit the name as required, either by typing it or by editing using the on-screen keyboard. Any changes made here will be reflected in the...
  • Page 22 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.

  • Page 23: The Barcode/Labels Screen

    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.
  • Page 24 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.

  • Page 25: The Documents Screen

    The Documents screen 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. Click on name and edit the name as required, either by typing it or by using editing the on-screen keyboard. Any changes made here will be reflected in the...
  • Page 26 True Weight: This shows the weight of the document or insert in the units editing the shown, and is linked to Thickness above. To enter a known weight, click settings. the ‘Computed’ button to uncheck the box, and then click the ‘True Weight’ (contd.) button. Enter the required figure in the units shown. Note that if this function is used Paper Weight will not be active.

  • Page 27: The Envelopes Screen

    The envelopes screen 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. Click on name and edit the name as required, either by typing it or by editing using the on-screen keyboard. Any changes made here will be reflected in...
  • Page 28 True Weight: This shows the weight of the envelope in the units shown, and editing the is linked to Thickness described on the previous page. To enter a known settings. weight, click the ‘Computed’ button to uncheck the box, and then click the (contd.) ‘True Weight’ button. Enter the required figure in the units shown. Note that if this function is used Paper Weight will not be active.

  • Page 29: The Configuration Screen

    5.9 The Configuration screen 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. Click the upper icon on the ‘Head’ part of the graphic (showing the 5.9.1 envelope icon).

  • Page 30: Setting The Inserter Options For The Inserter Unit

    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 Select ‘Save as Default’ to make this the default for all new setups. These settings then apply to ‘Load Default’...

  • Page 31: Setting The Document Options For The Feed Unit

    5.9.3 setting Click the upper icon on one of the numbered units (showing the document icon. This displays the list of available documents to select the document (see page 25 for creating documents). If the list is long, a ‘Find’ options for the box will appear to enable you to search the list using keywords.

  • Page 32: Setting The Feed Options For The Feed Unit

    5.9.4 setting Click on the lower icon of the numbered feed unit (showing the unit the feed icon), and the following dialog box appears: options for the feed unit Note that the options in the dialog box may vary from those shown, depending on whether the unit is a feeder or a folder.
  • Page 33 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.

  • Page 34: Setting The Module Options For A Folder

    5.9.5 setting If the unit is a tower folder or feeder folder, click on the uppermost section of the graphic (above the document icon), and the following the module options for a dialog box appears: folder Select ‘Save as Default’ to make this the default for all new setups.

  • Page 35: Setting The Output Options

    5.9.6 setting Ensure that the Output tab in the configuration screen is selected. This section allows you to set up batching on the output conveyor the output (where fitted). note: This screen will only be available to options personnel with supervisor access. This option is only available if a conveyor is fitted.

  • Page 36: Setting The Postage Options

    5.9.7 setting Ensure that the Postage tab in the configuration screen is selected. This section allows you to define weight groups for setting different the postage postage rates. The filled envelopes can then be diverted to different options 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.

  • Page 37: Setting The Miscellaneous Options

    5.9.8 Ensure that the Miscellaneous tab in the configuration screen is selected. This section allows you to select the required station for data setting the logging (where used), and also for the address carrying document. miscellaneous note: This screen will only be available to personnel with options supervisor access.

  • Page 38: The Job Screen

    5.10 The Job screen 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.

  • Page 39: The Users Screen

    5.11 The Users screen 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.

  • Page 40: The Statistics Screen

    5.12 The statistics screen 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...

  • Page 41: View Summary

    5.12.2 View Press the ‘Summary’ button to view the filtered data. Note that only valid events will be shown, ie. those that involved documents being fed summary (a machine configuration event, for example, would not be shown). 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.

  • Page 42: Data Logs

    5.12.4 Data Data Logs are created automatically whenever the machine is run. A separate log is created for Events, Document Outputs, Errors, OCR logs 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: Points to note Data is logged using only the barcode characters selected in the...

  • Page 43: Open Archive

    5.12.5 Open Select ‘Open Archive’ on the Statistics Diagnostics screen to display the details of archives, selected by date. Archives are automatically archive 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.

  • Page 44: Running The Job

    RUnnInG THe JOb Using the Now that you have finished defining a configuration, it can be associated with a Job. Click on Job in the Setup screen and select the configuration configuration, as described in the ‘The Job Screen’ on page 38. Running the 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 Job. Run screen, where you can commence operating, as described in ‘The Run Screen’...

  • Page 45: Daily Post (Handfeed)

    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.

  • Page 46: Setting Up The Machine

    seTTInG UP THe MaCHIne loading the paper hoppers Pull the weighted roller back and load Insert feeder (single, tower, OMR/ the inserts, ensuring they are fully down. Release the weighted roller so that it ‘tips’ barcode) the inserts into the pickup roller. An alternative heavier roller is also available (part no.

  • Page 47: Loading The Envelope Hopper

    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.

  • Page 48: Setting The Separator Gap

    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.

  • Page 49: Operator Settable Separator (Optional)

    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...

  • Page 50: Operator Maintenance

    OPeRaTOR MaInTenanCe 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.
  • Page 51 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.

  • Page 52: Cleaning Rollers And Sensors

    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.
  • Page 53 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 & transmitter - both halves must be cleaned. Open the perspex cover and front feeder cover, then lift the front-most green handle to raise the mechanism - this is...
  • Page 54 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. 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.
  • Page 55 Tower Unit There are sensors in three locations. Open the side cover and swing the green latch upwards to raise the roller platten. Clean both halves as shown. With the side cover open, swing the green latch forwards to open the daily post hopper.

  • Page 56: Maintaining The Wetting System

    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.

  • Page 57: Document Orientation Tables

    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.
  • Page 58 140 Operator Manual...

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