Neopost MaxiMailer HD Operator's Manual

Neopost MaxiMailer HD Operator's Manual

Automailer machine

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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 The OMR Code screen .............................................................21
5.6 The Barcode/Label screen ........................................................23
5.7
5.8
5.9 The Configuration screen .......................................................29
MaxiMailer HD 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 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
K1-0271-A Issue 5 January 2012
1

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Summary of Contents for Neopost MaxiMailer HD

  • Page 1: Table Of Contents

    5.9.4 Setting the feed options for the Feed unit ......32 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 MaxiMailer HD Operator Manual K1-0271-A Issue 5 January 2012...
  • Page 2 Cleaning rollers and sensors ..........50 Maintaining the wetting system ..........54 10. Technical Specification ............. 55 10.1 Inserter Head ..............55 10.2 Mechanical & Electrical ............59 Glossary of Terms ..............61 Document Orientation Tables ............ 66 Declaration of Conformity ............68 MaxiMailer HD Operator Manual...
  • Page 3: Introduction

    Save this handbook carefully, so that the information it contains may be available at all times. Pictograms General Warnings Warning of danger from electricity or electrical shock Information / Note indicating important information regarding the handling of the machine. MaxiMailer HD Operator Manual...
  • Page 4: Notes On The Use Of This Handbook

    In not adhering to this handbook, there is the danger of • an electrical shock, • injuries from the intake at the rotating rollers, • damage to the machine. IMPORTanT: To switch the machine off in an emergency, open any cover. MaxiMailer HD Operator Manual...
  • Page 5: General Safety Notes

    Prior to cleaning the exterior of the machine, it should be disconnected from the power supply. When cleaning the machine, do not use liquid or spray machine cleaners, but only a cloth dampened with water. When cleaning sensors use only non-flammable airdusters, eg. part number Cleaning sensors E0070A. Other types may use flammable propellants, which could result in fire or explosion. MaxiMailer HD Operator Manual...
  • Page 6: End Of Life

    More particularly, certain materials and components of waste electrical and electronic equipment needs selective treatment as their injudicious handling or disposing of on or into land, water or air would represent a major threat to the environment and human health. MaxiMailer HD Operator Manual...
  • Page 7 For more information on the correct disposal of this product please contact your local dealer. MaxiMailer HD Operator Manual...
  • Page 8: Technical Specification

    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 Tower Unit Lifting or handling must only be carried out by competent persons using appropriate means. MaxiMailer HD Operator Manual...
  • Page 9: Machine Layout Guide

    If other hoppers are loaded, further forms can be collated. 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. MaxiMailer HD Operator Manual...
  • Page 10: Parts Identification

    Insert/collate area Envelope hopper Filled envelope tray Cupboards for PC and fluid bottle Note: Station 1 is the first feed unit after the insert/collate area. Unless additional feeders or folders are fitted, this will be the DTI. MaxiMailer HD Operator Manual...
  • Page 11: Operating Instructions

    This is to optimise the movement of large packs. It will remain at the lower speed for the remainder of the job, even if subsequent pack sizes remain smaller. To resume operating at optimal speed, press the Run button whilst the machine is running. MaxiMailer HD Operator Manual...
  • Page 12: Starting The Operating Program

    User button note: new operators and passwords can be only be entered or edited by authorised personnel with supervisor access. This is detailed in section 5.11 ‘The Users screen’ on page 39. MaxiMailer HD Operator Manual...
  • Page 13: The Run Screen Explained

    To view and adjust the settings for the envelope and document inserters, press on the relevant part of the machine graphic (see the following page for details). MaxiMailer HD Operator Manual...
  • Page 14: To Change The User

    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). MaxiMailer HD Operator Manual...
  • Page 15: To Adjust The Envelope Inserter Settings

    Adjustment of strength of blower fan for envelope opening. Options are Off/Low/High (default is low). Use High for single sheet into C4. cont. k. The sequence of the inner or outer finger pairs, whether inner or outer pair enters the envelope first. This slight delay can assist opening the envelope throat, depending on its design. MaxiMailer HD Operator Manual...
  • Page 16 Important: All fine adjustments apply only to the current job and will not affect any other jobs. MaxiMailer HD Operator Manual...
  • Page 17: To Adjust The Document Inserter Settings

    The settings available will vary between feeders settings and folders. Press on the feeder or folder on the machine graphic to display the fine tuning screen. DTI or feeder (of any type) No fine tuning of the unit part of the feeder is available MaxiMailer HD Operator Manual...
  • Page 18 Important: All fine adustments apply only to the current job and will not affect any other jobs. MaxiMailer HD Operator Manual...
  • Page 19: The Setup Screen

    Allows hardware set-up of the machine, and diagnosis of various parts. Only available to personnel with engineer access, and described in detail in the machine Service Manual. admin Allows administration of various machine functions. Run screen Press this to take you back to the Run Screen. MaxiMailer HD Operator Manual...
  • Page 20: The List Box

    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). MaxiMailer HD Operator Manual...
  • Page 21: The Omr Code Screen

    If ‘As fed’, it must be in the direction and orientation as specified in the unit settings in ‘Configuration’ – this mostly applies to legacy jobs. Set the Code type (1-track or 2-track), Number of marks, Gate orientation (top, bottom, left or right, as shown below): MaxiMailer HD Operator Manual...
  • Page 22 After making any changes, press 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. MaxiMailer HD Operator Manual...
  • Page 23: The Barcode/Label 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 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: (Not available for Neopost 3). 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).
  • Page 25: The Documents Screen

    Pre-folded leaves: If the insert consists of more than one leaf (eg. a ‘Z’ folded flyer), click the button and enter the number of leaves. Thickness: If the insert is a booklet or other thick material, press the ‘Computed’ button to uncheck the box, and then press the ‘Thickness’ button. Enter the required figure in mm. Note that if this function is used Paper Weight will not be active. MaxiMailer HD Operator Manual...
  • Page 26 1. Minimum document width in 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. MaxiMailer HD Operator Manual...
  • Page 27: The Envelopes Screen

    Thickness: If the envelope is of very thick material or of unknown weight, press the ‘Computed’ button to uncheck the box, and then press the ‘Thickness’ button. Enter the required figure in mm. Note that if this function is used Paper Weight above will not be active. MaxiMailer HD Operator Manual...
  • Page 28 Press the ‘Save as Default’ button if you wish this to be the setup that new envelopes will default to. When all editing is complete, press the save button at the bottom of the screen, and then the exit button to return to the list box. MaxiMailer HD Operator Manual...
  • Page 29: The Configuration Screen

    6 stations, use the scroll arrows to move sideways. Select the required envelope and press ‘Ok’ Note: An error will occur if an envelope that is used in any configuration has been deleted from the list box in the Setup screen (see page 19). MaxiMailer HD Operator Manual...
  • Page 30: Setting The Inserter Options For The Inserter Unit

    Options are Off / Always / Unseal OMR Select / Off Flap Open (if ‘Off’ is selected, flap is closed without sealing). Deskew: The setting of the amount of envelope deskew required. Note a higher level will slow the machine more. Item ID: If available for setting must be set to Item ID 1. MaxiMailer HD Operator Manual...
  • Page 31: Setting The Document Options For The Feed Unit

    ‘Previous’ buttons will be active. Select the required document and click ‘Ok’ 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). MaxiMailer HD Operator Manual...
  • Page 32: Setting The Feed Options For The Feed Unit

    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. MaxiMailer HD Operator Manual...
  • Page 33 Cascading (not applicable to DTI): 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. MaxiMailer HD Operator Manual...
  • Page 34: Setting The Module Options For A Folder

    (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. MaxiMailer HD Operator Manual...
  • Page 35: Setting The Output Options

    Pause time is the number of seconds before the machine auto-restarts. After making any changes, press the save button at the bottom of the screen, and then the exit button to return to the list box. MaxiMailer HD Operator Manual...
  • Page 36: Setting The Postage Options

    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 & 27). MaxiMailer HD Operator Manual...
  • Page 37: Setting The Miscellaneous Options

    This allows some adjustment of reading of the label position. Units are in milliseconds. 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. MaxiMailer HD Operator Manual...
  • Page 38: The Job Screen

    To create a new configuration, see ‘The Configuration Screen’ on page configuration late 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 conjunction with ID field label. MaxiMailer HD Operator Manual...
  • Page 39: The Users Screen

    To provide access to all rôles, select ‘Superuser’. rôles for further explanation of the rôles, contact Technical support. After making any changes, click the save button at the bottom of the screen, and then the exit button to return to the list box. MaxiMailer HD Operator Manual...
  • Page 40: The Statistics Screen

    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: MaxiMailer HD Operator Manual...
  • Page 41: View Summary

    The ‘Previous’ button shows events up to the last & Previous new logon. If a new archive is opened (see page 43), the ‘Previous’ sessions button will restore the events that were displayed prior to its opening. MaxiMailer HD Operator Manual...
  • Page 42: Data Logs

    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. Data Log files are created on the computer disk in the following location: C:\Program Files\Pfe\Maximailer Plus\Data\DataLogs for full details of analysing Data logs, see document ‘Data log Specification’. MaxiMailer HD Operator Manual...
  • Page 43: Open Archive

    (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. MaxiMailer HD Operator Manual...
  • Page 44: Running The Job

    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. MaxiMailer HD Operator Manual...
  • Page 45: Daily Post (Handfeed)

    - 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: 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. MaxiMailer HD Operator Manual...
  • Page 46: Setting Up The Machine

    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. MaxiMailer HD Operator Manual...
  • Page 47: Loading The Envelope Hopper

    ‘tip’ into the pickup roller. Adjust the side guide wheel to give 1 - 2mm clearance across the width of the envelopes. MaxiMailer HD Operator Manual...
  • Page 48: Setting The Separator Gap

    C = 1.5 to 2.5mm the thickness of D = 2.5 to 4.0mm the insert. (A - C only on Tower Feeder)  Most jobs will use position A. If you use the wrong setting, an error will appear on the control panel. MaxiMailer HD Operator Manual...
  • Page 49: Operator Maintenance

    Turn the green knobs on the tower feeder to wind the crashed document into the cavity ahead – it can then be easily removed. MaxiMailer HD Operator Manual...
  • Page 50: Cleaning Rollers And Sensors

    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). MaxiMailer HD Operator Manual...
  • Page 51 Open the perspex cover, then lift the front-most green handle to raise the mechanism - this is held in the raised position by a latch. View looking rearwards View looking forwards Lower the mechanism to clean the sensors shown. cont. MaxiMailer HD Operator Manual...
  • Page 52 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. MaxiMailer HD Operator Manual...
  • Page 53 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. Looking rearwards into the cavity, raise the central overguide to access the envelope flap sensor. MaxiMailer HD Operator Manual...
  • Page 54: Maintaining The Wetting System

    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. MaxiMailer HD Operator Manual...
  • Page 55: Technical Specification

    C5/C6 (114mm x 229mm) envelope). Up to 3000 envelopes per hour (based on 1 x A4 folded sheet with 1 x enclosure into a C5/C6 (114mm x 229mm) envelope). Speeds for other conditions available on request. MaxiMailer HD Operator Manual...
  • Page 56 Max.165mm (6 ") Max.22mm ( ") Horizontal portion of throat Min. 98.5mm (3 7/8") Min.10mm ( ") Max. = Envelope Width - 75mm (3") Commercial style envelope Envelope Width Max. 264mm (10 ") Min. 225.5mm (8 7/8") MaxiMailer HD Operator Manual...
  • Page 57 Window width to be less than 40% of envelope width. The bottom flap of the envelope should be in-line or below the top of the seam shoulders Good example Bad example - Out of Specification MaxiMailer HD Operator Manual...
  • Page 58 Maximum distortion allowable on a twisted envelope to be 10mm ") when envelope measured sitting flat on a table Built-in wetter tank, automatically pump-fed by 10-litre wetter envelope container located in stand. Optional low-level float switch sealing fluid available. MaxiMailer HD Operator Manual...
  • Page 59: Mechanical & Electrical

    Input Current Head: 0.85A Head: 1.6A Fuse Rating T6.3A T10A (Insert Head) Weights (nett): Inserter Head 97Kg unpackaged 122Kg packaged Operating Temperature: 18 - 28 deg C (64 - 82 deg F) Operating humidity: 30 - 80% RH MaxiMailer HD Operator Manual...
  • Page 60 6. Material processed directly from laser printers may have high levels of static causing material to stick together. If double feeding occurs, then Hi-Grip separators may be required - contact IPSS department. MaxiMailer HD Operator Manual...
  • Page 61: Glossary Of Terms

    The number of enclosures can range from 0 to the limit imposed by the number of available feeders, whilst observing the overall pack thickness. Once the document set has been inserted into an envelope it is called mail set. MaxiMailer HD Operator Manual...
  • Page 62 DD sensors exist on feeders (double sheet detection). Currently DD detection on Neopost inserting systems perform relative measurements, which means that they need a cycle to ‘learn' the thickness of a sheet. Also the length of the document is measured so partly overlapping sheets will be detected.
  • Page 63 (accumulate document set, fold and insert) and have a single point of control. Insert‘n Frank™ Interface for the Neopost franking system. (mailing system) A job is an actually produced collection of mail sets based on a certain job definition at a certain point in time for a specific purpose. It consists •...
  • Page 64 A test run is intended to validate the settings of the inserting system: • Inspect and adjust the stop position of the envelope. • Check the fold settings for one set. • Check whether the address is correctly positioned behind the envelope window. MaxiMailer HD Operator Manual...
  • Page 65 Z-fold (also A Z-fold means that a document is folded twice in such a way that each known as zigzag folded flap is on a different size of the folded document, resulting in fold) a Z-shape. This fold is illustrated below. The position of both folds is adjustable. MaxiMailer HD Operator Manual...
  • Page 66: Document Orientation Tables

    Shaded areas denote folds that give incorrect address orientation in window of standard envelope. Reverse printing and/or non-standard window envelopes may permit use. note: For some complex jobs, not all paper trays may be loaded in the same way. MaxiMailer HD Operator Manual...
  • Page 67 MaxiMailer HD Operator Manual...
  • Page 68: Declaration Of Conformity

    DECLARATION OF CONFORMITY Maximailer HD MaxiMailer HD Operator Manual...
  • Page 69 MaxiMailer HD Operator Manual...

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