Table of Contents
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TABLE OF CONTENTS
1
Health, Safety and Environment ...................................................... 3
1.1
Precautions and Safety Issues ................................................... 3
1.2
Country Specific Conditions ...................................................... 4
1.3
End of Life .............................................................................. 4
2
Functional Description ..................................................................... 6
2.1
Overview ................................................................................ 7
2.1.1 Feeder (1) .................................................................... 7
2.1.2 Collating Area (2) .......................................................... 8
2.1.3 Divert area(3) ............................................................... 8
2.1.4 Folder (4) ..................................................................... 8
2.1.5 Inserter (6) .................................................................. 8
2.2
Operating Controls .................................................................. 9
2.3
Display Buttons ...................................................................... 10
2.4
Software Description ............................................................... 10
2.4.1 Main Menu ................................................................... 10
2.4.2 Job Info ...................................................................... 12
2.4.3 Counters ..................................................................... 13
2.4.4 Display Settings ........................................................... 13
2.4.5 Job Menu ..................................................................... 14
2.4.6 Supervisor Menu .......................................................... 14
3
Operating Instructions .................................................................. 20
3.1
Installation ............................................................................ 20
3.2
Preparation ........................................................................... 20
3.2.1 Document Feed Trays ................................................... 20
3.2.2 Conveyor Stacker ......................................................... 21
3.3
Starting Up ............................................................................ 21
3.4
Loading Documents ................................................................ 22
3.4.1 Document Orientation ................................................... 22
3.4.2 Side Guides ................................................................. 23
3.4.3 Document Separation .................................................... 23
3.4.4 Filling the Document Feed Tray ...................................... 24
3.4.5 Adjustment of the Document Stoppers ............................ 24
3.5
Loading Envelopes .................................................................. 25
3.5.1 Adjusting Side Guides ................................................... 25
3.5.2 Envelope Separation ..................................................... 25
3.5.3 Feeding Envelopes ........................................................ 26
3.6
Sealing Envelopes .................................................................. 26
3.7
Job Selection or Fill & Start ...................................................... 27
3.7.1 Using Fill & Start .......................................................... 27
3.7.2 Select Another Job ........................................................ 29
3.8
Run the Daily Mail .................................................................. 30
3.9
Create a Job .......................................................................... 31
3.9.1 Job Settings ................................................................. 32
3.9.2 Envelope Settings ......................................................... 32
3.9.3 Document Settings ....................................................... 33
3.9.4 Fold Settings ................................................................ 34
3.9.5 Optical Mark Recognition Settings (Option) ...................... 36
3.9.6 Double Feed Control Settings ......................................... 37
3.9.7 Job Name .................................................................... 38
1
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Summary of Contents for Neopost Carat Prisma
- Page 1 TABLE OF CONTENTS Health, Safety and Environment ............3 Precautions and Safety Issues ........... 3 Country Specific Conditions ............4 End of Life ................4 Functional Description ..............6 Overview ................7 2.1.1 Feeder (1) ..............7 2.1.2 Collating Area (2) ............8 2.1.3 Divert area(3) ...............
- Page 2 3.9.8 Mailing (Franking) Settings (Option) ........ 39 3.10 Edit a Job ................40 3.11 Copy a Job ................40 3.12 Delete a Job ................41 Options ..................42 Activate an Option ..............42 Optical Mark Recognition (OMR) ..........42 4.2.1 General ............... 42 4.2.2 Alignment ..............
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Page 3: Precautions And Safety Issues
HEALTH, SAFETY AND ENVIRONMENT Precautions and Safety Issues Thoroughly read this operator manual, before using this machine. According to the European Guideline for machine safety (EC98-37), this operator manual must be available in the national language(s) of the country where the machine is delivered. -
Page 4: Country Specific Conditions
Conventions Warning This symbol: • Identifies situations where improper use of the machine can result in personal injury or permanent/catastrophic damage to the machine. • Indicates that the operator manual should be consulted. Warning This symbol indicates a danger caused by high voltage. Note A note gives additional relevant information. - Page 5 In order to facilitate collection and treatment separated from normal domestic waste, electrical and electronical 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 electronical waste Equipment produced after August 13, 2005.
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Page 6: Functional Description
FUNCTIONAL DESCRIPTION The system feeds, folds and inserts documents into envelopes and then seals and stacks the envelopes. Automatic monitoring ensures the correct number of inserts per envelope. The machine is a sophisticated folding and inserting system which can process large quantities of mail rapidly and easily. -
Page 7: Overview
Overview The system consists of the following parts: Feeder Collating area Divert area Folder Envelope feeder Inserter Envelope exit (including conveyor stacker) 2.1.1 Feeder (1) The Feeder is the feeding part of the system. There are two types of feeders available: the automatic and the special feeder. -
Page 8: Collating Area (2)
2.1.2 Collating Area (2) After feeding, the documents are gathered and aligned in the collating area. 2.1.3 Divert area(3) The Divert area automatically throws out incorrect sets of documents. In this way the system does not need to stop. Correct sets will be transported to the Folder unit. 2.1.4 Folder (4) The Folder unit folds the documents. -
Page 9: Operating Controls
Operating Controls conveyor stacker locking handle Folder loc cover air plugs for cleaning the sensors unlocking lever for loc handle for manual envelope transport power inlet, power switch unlocking handle for rollers envelope track inserter cover water reservoir RS232 connector / USB / modem bellows for cleaning sensors display (operator panel) side cover (opened) -
Page 10: Display Buttons
Display Buttons The machine has a graphical touch screen. There are three buttons mounted at the display: • A: the clear key When the clear key is pressed during processing documents, the system will stop feeding documents after completing the set. The set will be inserted resulting in a cleared system which is ready to process a new job. - Page 11 The job information function is available in all the menus where the button is shown. • : go to the “job selection” menu to select another job (see 3.7.2 ”Select Another Job” on page 29). • : go to the “test run” menu to perform a test run (see ”Perform a Test Run”...
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Page 12: Job Info
2.4.2 Job Info To enter the “job info” menu, press This menu displays all relevant information about the selected job. If the optional insert‘n Frank™/ Insert & Mail is used the “insert‘n Frank™/Insert & Mail info” menu is also available using the button. -
Page 13: Counters
2.4.3 Counters To enter the “counters” menu, press from the “main menu (1)”. The “counters” menu shows the following functions: • : press this button to reset the daily job counter and stop counter to zero. • : press this button to enter a stop value. -
Page 14: Job Menu
2.4.5 Job Menu After pressing the button a login menu opens. To prevent jobs being edited or deleted without informing the ‘job owner’, this menu is protected by a PIN-code. The PIN-code is 2546. When a wrong pin code is entered, the cursor is set to the first number to try again. - Page 15 After entering the correct pin code the “supervisor menu” appears. This menu enables checking and configuring the system. The “supervisor menu” shows the following functions: • : shows system information, like: The flex certificate, used for OMR The counter since last visit: the counter value since the last service visit The last error generated by the system The screen shows a button : this shows the software versions that are...
- Page 16 Job Settings (Supervisor) Caution Job settings normally will be changed by a service engineer only. Therefore first consult the supplier’s Helpdesk before changing any settings. Changes to the job settings can result in malfunctioning of jobs. The “job settings” menu (supervisor) can be opened from the “supervisor menu”.
- Page 17 • Anticipation call for the envelope is used. That means that a (folded) set is leaving the Feeder already before the envelope is ready on the insert position. In mode 1 the envelope is on the insert position already before the set leaves the Feeder. It is advised to use Mode 1 with a paper thickness of 65 g/m or less, a document length of 12 inch (305 mm) or higher, and for situations where Mode 2 is not functioning...
- Page 18 • The document directly beneath this document must be at least 60 mm (2.4 inch) longer than the BRE. • The upper document must be longer than the set address fold. • The folding mode is either single fold or letter fold (no Z-fold). •...
- Page 19 Note Remove all paper and close all covers before calibration. • : use this function to align and test the OMR reading head (see ”OMR Test” on page 19). OMR Test The “OMR test” menu can be opened from the “test menu”.
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Page 20: Installation
OPERATING INSTRUCTIONS Installation Caution You can severely damage the machine if it is connected to the incorrect power supply. Before plugging in the machine, check if the local voltage is the same as the voltage mentioned on the type plate. Preparation 3.2.1 Document Feed Trays... -
Page 21: Conveyor Stacker
3.2.2 Conveyor Stacker Place the conveyor stacker in position: Position the fork in a forward direction. Move the conveyor as indicated by the arrows. Lift the conveyor with the suspension hooks over the two rods (upper and lower) and lower Ensure that the fork hooks onto the eccentric. -
Page 22: Loading Documents
Loading Documents 3.4.1 Document Orientation Type of documents one document hopper swap two documents document + enclosure Fold type no fold single fold Address carrier in top feeder. Address carrier in top linked Address carrier in top feeder. Address carrier in top feeder. letter fold double Face up and leading. -
Page 23: Side Guides
3.4.2 Side Guides To adjust the side guides it is best to remove the document feed tray from the feeder as follows: Push handle A downwards. Lift the document feed tray upwards to unhook it and then pull it out from the feeder. Loosen the knob B half a turn. -
Page 24: Filling The Document Feed Tray
The document separation for special feeders must be adjusted manually as follows: Push the knob B forward until it clicks. Open the left-hand side guide A by turning it downwards. Place a document on the feed tray and slide it about 60 mm (2.4 inch) into the system (turn the knob B counter clockwise if the separation is set to narrow). -
Page 25: Loading Envelopes
Initially the document stoppers are adjusted for position B. In this position a wide variety of documents can be handled (max. 297 mm; 11.7 inch) and adjustment is not needed. When a job is selected in which a different stopper position has been programmed, the operator has to put the document stoppers in the correct position as indicated by the display. -
Page 26: Feeding Envelopes
3.5.3 Feeding Envelopes Place the bottom envelope between the rollers (flap down and trailing - bottom side of envelope pointing to the machine). Loosen the stack of envelopes and place the stack on top of the bottom envelope. Shift envelope support B in or out, so that the flap side of the envelope is lifted approximately 20 mm (0.8"). -
Page 27: Job Selection Or Fill & Start
Job Selection or Fill & Start When you are ready with the preparations (paragraph 3.2 to 3.6) continue using the Fill & Start function (see 3.7.1 ”Using Fill & Start” on page 27) or select another job and perform a test run (3.7.2 ”Select Another Job” on page 29). The Fill &... - Page 28 Insert Position Note This adjustment must only be checked in case of problems or when changing the envelope type. Lift the locking lever of the loc and pull the loc into the vertical position. The flap folding line must be positioned under the green indicator C.
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Page 29: Select Another Job
If necessary, press the Up or Down button to adjust the address position. Each key stroke brings the address 1 mm (0.04 inch) with a maximum of 12 mm (0.48 inch) lower or higher. If the required address position is beyond the maximum range of 24 mm (0.96 inch), the Fill &... -
Page 30: Run The Daily Mail
Perform a Test Run To perform a test run: Press to display the “test run” menu. A message can appear: “Set manual feeding” or “Set automatic feeding”. In that case: Check if the daily mail handle is in the correct position (see 3.8 ”Run the Daily Mail”... -
Page 31: Create A Job
Turn left side guide A of the upper tray down. The Daily Mail handle B will become visible. Move the handle to to enable the Daily Mail function. Turn left side guide A upwards. Place the document or document set in the feeder. -
Page 32: Job Settings
Press to save the job with the entered settings under the specified job number and name. To name a job, see 3.9.7 ”Job Name” on page 38. Press to perform a test run with the new job settings (see ”Perform a Test Run”... -
Page 33: Document Settings
The envelope height can be set between 90 mm (3.5 inch) and 162 mm (6.38 inch). • Press to set a job without inserting the documents in envelopes (no envelope mode). This can be useful for jobs, where documents only have to be sorted and/or folded. -
Page 34: Fold Settings
• Press to link two feeders. This function enables to fill two adjacent feeders with the same documents. When the first feeder is empty, the system automatically swaps to the other feeder. Press to select two adjacent feeders. The selected feeders will be highlighted. - Page 35 • In the second fold setting screen you can select the fold type. The following choices are available: No fold (no settings required) Single fold Letter fold Double parallel fold Zig-zag fold Except when no fold is required, the display shows a simple diagram of the document with the fold positions.
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Page 36: Optical Mark Recognition Settings (Option)
3.9.5 Optical Mark Recognition Settings (Option) For a full function description of Optical Mark Recognition (OMR), see 4.2 ”Optical Mark Recognition (OMR)” on page 42. Flex-OMR is also optional and can read customer specific codes. In the “OMR settings” menu it is possible to enable or disable the OMR function and to adjust the basic settings for OMR. -
Page 37: Double Feed Control Settings
• Max. sheets: select the maximum amount of sheets in the set of documents using the arrow buttons. Note The maximum number of sheets in a set is 25. When the number of sheets exceeds 8 or 10, depending on the fold, the document can not be folded anymore. In this case, the maximum length of sheets is 156 mm (6.1 inch) for a C5 envelope. -
Page 38: Job Name
If the DFC is on you can set Continue on double on or off using the button. If Continue on double is on (“yes”), the machine will not stop if two sheets are feeded instead of one. The document-set containing the double sheets will be diverted. When a job is started, the first document taken per feeder is used for a reference measurement. -
Page 39: Mailing (Franking) Settings (Option)
3.9.8 Mailing (Franking) Settings (Option If this machine is connected to a mailing (franking) machine, this option allows you to select the mailing (franking) mode. Press the button to select: • Pass through The mailing (franking) machine will let the envelopes pass through without postage (franking). - Page 40 3.10 Edit a Job To edit an existing job: Press from “main menu (2)” (see 2.4.1 ”Main Menu” on page 10). Enter the pin code. The “job menu” opens (see 2.4.5 ”Job Menu” on page 14). Press The “edit job” menu appears. Press the arrows if you want to select an other job number.
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Page 41: Delete A Job
Note You can only copy job settings to new jobs. Press for details of the job to copy from. Press to copy the job settings. If all jobs are programmed the display shows “No more free jobs”. It is possible to copy a Fill & Start job into a job. Before a Fill & Start job can be copied Fill &... -
Page 42: Options
OPTIONS Activate an Option To activate a new option: From the “supervisor menu” choose Software options are enabled using license codes. These license codes, together with the identification number of the machine enable the relevant options. The enabled and available software options are displayed in this screen. Contact your dealer for information about these license codes. -
Page 43: Alignment
4.2.2 Alignment Reading Head Position The horizontal position of the reading head must be aligned to the same position of the printed marks on the documents. To align the reading head, proceed as follows: Open the “OMR test” menu from the “Test menu”... -
Page 44: Document Orientation
4.2.3 Document Orientation Switch on the OMR-function and set the position of the reading marks as described in “Optical Mark Recognition Settings (Option)” on page 36. Document orientation: Type of documents Fold type direction no fold single fold address start reading first page stop reading letter fold... - Page 45 Minimum Code / Basic Commands The minimum code is one mark in one line (insert). However for reliability it is advised to use at least 2 marks. The first line is the start mark. A mark printed on the second line means insert. No mark on the second line means accumulate.
- Page 46 Additional Marks When it is required to control more functions in the inserter system, the use of more marks is needed. Start mark The following additional functions are possible via Insert/accumulate software options: Divert mark • Divert mark (divert & continue) Stop mark Selective feed 1 •...
- Page 47 Safety Mark The safety mark is used as an extra security. With Normal paper flow Skewed paper flow skewed paper the reading head can miss part of the reading code. In these situations the safety mark is Start mark Start mark not read, and the system will give an error.
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Page 48: Online Services
Online Services 4.3.1 General The folding and inserting system can be equipped with Online Services. This option enables the machine to connect to a central server. During the connection data is downloaded to and uploaded from the machine. The machine always initiates the connection, it is not possible to make a connection from outside to the machine. -
Page 49: Messages
The “connection” menu shows the following functions: • : opens the “history” menu to view the connection history (see ”History” on page 49). • : this button appears when the machine received new messages and opens the “messages” menu (see 4.3.4 ”Messages” on page 49). History The “history”... -
Page 50: Configuration Menu
• In case of a new job press to select a free job number (see 3.9 ”Create a Job” on page 31). Press to confirm the selected job number or press to return to message menu. After conforming the installation of the new software or new job the “message” menu appears. -
Page 51: Maxifeeder
• Volume of modem: set the modem volume. Press to change the volume of the speaker. Do not set the volume to zero as the sound of the modem is helpful during remote assistance. Press to confirm modified settings. MaxiFeeder™ 4.4.1 Function The maxiFeeder™... -
Page 52: Adjust Side Guides
4.4.3 Adjust Side Guides Adjust the side guides: Take a stack of documents/BREs and place them in the feed tray. BREs with flap down and leading (top side pointing to machine). Adjust the side guides by turning the thumb wheel A so the documents/BREs just fit and can move without resistance. -
Page 53: Insert & Mail (Insert'n Frank™)
Shift the feeding plate C to the rear position. Loosen the stack of documents and place them in the feeder. BREs with flap down and leading (top side pointing to machine). The feeding plate assembly will be shifted up automatically (when the system starts processing) until documents/BREs are underneath the rubber paper pullers. -
Page 54: Maintenance
MAINTENANCE Disconnect the mains power supply before performing any maintenance. The user must not attempt to service the appliance beyond that described in this operator manual. All other servicing must be carried out by qualified service personnel only. Please contact your authorized distributor. Operator Maintenance Maintenance Maintenance... -
Page 55: Fault Finding
FAULT FINDING Error Messages When an error occurs the display shows a screen showing the following information: • An indication of the area in which the error occurred • An error description • A suggested solution behind the pointing hand Press to view more information about the occurred error and about the possible actions to... -
Page 56: Clearing Stop
Clearing Stoppages Stoppages can occur in the following areas: Feeder area Collating area Folder area Lower envelope track Sealing and inserting area Exit area Envelope hopper For clearing of stoppages, six system sections can be opened: loc cover, to reach the exit area inserter cover, to reach the sealing and inserter area collator arm, to reach the collating area... -
Page 57: Envelope Hopper
6.2.2 Envelope Hopper When an envelope gets stuck in this area, remove the envelope as follows: Pull down small lever B. Pins C will come down. Push lever A to the right and hold it. Pins C will go up. Remove the stuck envelope. -
Page 58: Folder
6.2.4 Folder When a stoppage occurs in the Folder, remove the documents from the Folder as follows: Push the lower end of the locking handle A to open the Folder cover B. Remove the documents from the Folder. Close the Folder cover. Press to reset the error and restart the job. - Page 59 Note When contacting the service organization, you will also be asked for the last error message and the software version of the installed software. To determine the software version, refer to 2.4.6 ”Supervisor Menu” on page 14. Symptom Possible cause Remedy Reference The system...
- Page 60 Symptom Possible cause Remedy Reference Flap is wrinkled Envelope not within Check specifications “Document and sometimes specifications. and change Specifications” on not opened. envelopes if needed. page 62 Flap sticks. Store envelopes “Document according to Specifications” on specifications. page 62 Flap curled.
- Page 61 Symptom Possible cause Remedy Reference Flap not Water level low. Check water level, “Sealing Envelopes” on sufficiently refill if needed. page 26 moistened. Brushes dry. Check brushes, “Sealing Envelopes” on replace if needed by page 26 the extra soaked set. Brushes dirty.
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Page 62: Specifications
SPECIFICATIONS Technical Specifications Type inserter system for medium office use. Theoretical max. 4000 inserts per hour, depending on application. speed Power consumption 100V AC/50Hz/3.0 Amps. 115V AC/50/60Hz/3.0 Amps. 230V AC/50Hz/1.5 Amps. Fuse 100/115 Vac: T 5.0 A, 125 V Time lag, 5.0 Amps. rated current, 125 V. 230 Vac: T 2.5 A H, 250 V Time lag, 2.5 Amps. -
Page 63: Envelope And Insert Specifications
Paper size Minimum width: 130 mm (5.1") Maximum width: 242 mm (9.5"), when folded 230 mm (9.1") Minimum length: 90 mm (3.5") Maximum length: 356 mm (14") Folding capacity Single fold - 10 sheets (max. 80 g/m²) Letter fold / Z-fold - 8 sheets (max. 80 g/m²) Double parallel fold - 4 sheets (max. - Page 64 • We recommend that materials to be handled are stored at a temperature of 20°C (68°F) with a relative humidity factor of 50%. If difference in temperature occurs between store room and mailing area, the material has to be stored near the machine at least 24 hours before use.
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Page 65: Terminology
TERMINOLOGY Term Description Address carrier The address carrier is the document that carries the address of the person for who the mail-set is meant. The address carrier can consist of one or more sheets, from which at least the first sheet must contain the address. - Page 66 DFC sensors exist on Feeders (double sheet detection). Currently DFCs on Neopost inserting systems perform relative measurements, which means that they need a cycle to 'learn' the thickness of a sheet.
- Page 67 Term Description Feeder linking The ability to load two feeders with the same document type where the Inserting System automatically switches to a second feeder when the first feeder is empty and vice versa. In the mean time the first feeder can be refilled, so the inserting system can keep running without having to stop for refilling the feeders.
- Page 68 Term Description Linking See Feeder Linking. MaxiFeeder™ Feeder with high capacity feed tray (e.g. 2000 sheets A4 80gr). Multifeed The feature of an Inserting System in which more than one sheet is taken from a Feeder. Optical Mark Recognition OMR code Standard 1-track OMR code definition.
- Page 69 Term Description Tray Contains a stack of paper for a printer or inserter. This paper is supplied to the machine for further processing. Vertical transport The vertical transport section between feeders and collator. Z-fold A Z-fold means that a document is folded twice in such a way that each folded flap is on a different size of the folded document, resulting in a Z-shape.
- Page 70 Address: De Tijen 3, 9201 BX Drachten The Netherlands, herewith declares that the: DS-80, M7000, Carat Prisma, FPi 5500, FD 6402, • which this declaration refers to, is in accordance with: the conditions of the Low Voltage Directive 73/23/EEC, modified by the directive 93/68/EEC, •...
- Page 71 EC DECLARATION OF CONFORMITY FOR ELECTRICAL PRODUCTS (According to Annex III B of the Low Voltage Directive) Manufacturer: Neopost Technologies BV Address: De Tijen 3, 9201 BX Drachten The Netherlands, herewith declares that the: MF-1, • which this declaration refers to, is in accordance with: the conditions of the Low Voltage Directive 73/23/EEC, modified by the directive 93/68/EEC, •...
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Page 72: Index
Index offset 17 orientation 22 separation 23 settings 33 address carrier 65 specifications 62 address position 28, 65 stopper 24 document orientation extended folding 22 bellows 9, 54 normal 22 BRE offset 17 OMR 44 brush 26 document stoppage brush replacement 54 see stoppage business reply envelope 65 document-set 65... - Page 73 automatic 7, 23 install 20 letter fold 67 link 34 loading envelopes 25 load 24 loc 9 remove 23 side guides 23 special 7, 24 main menu 10 feeder linking 67 maintenance 54 Fill & Start 27 maxiFeeder™ 51, 68 fill water reservoir 26 document separation 52 flap closer 18...
- Page 74 troubleshooting 58 paper quality 62 paper size 63 volume acoustic signals 13 photocell calibration 18 power consumption 62 power switch 9 water reservoir 9 reading head position 43 Z-fold 69 RS232 connection 9 safety 3 seal envelopes 26 sensor 9 sensor dusty 54 set automatic feeding 30 set manual feeding 30...
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