Table of Contents
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TABLE OF CONTENTS
1
Introduction ............................................................................... 3
1.1
1.2
2.
Safety Notes ............................................................................... 4
2.1
2.2
3.
Technical Specifi cation ............................................................... 8
4.
Machine Layout Guide ................................................................. 9
4.1
4.2
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
5.10 The Job screen .....................................................................38
5.11 The Users screen ..................................................................39
140 Operator Manual
Pictograms ........................................................................... 3
Notes on the Use of this Handbook .......................................... 4
General safety notes .............................................................. 5
End of Life ............................................................................ 6
Description of machine ........................................................... 9
Parts identifi cation ................................................................10
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
5.3.3 To adjust the Envelope Inserter settings ..........................15
5.3.4 To adjust the Document Inserter settings ........................17
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
The Confi guration screen .......................................................29
5.9.1 Confi guring the inserter. ................................................29
5.9.2 Setting the inserter options for the Inserter unit ...............30
5.9.3 Setting the document options for the Feed unit ................31
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
1
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Table of Contents
Summary of Contents for Hasler PS-140
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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 Specifi cation ............... 8 Machine Layout Guide ..............9 Description of machine ............ - Page 2 5.12 The Statistics screen .............40 5.12.1 Filter ................40 5.12.2 View Summary ............41 5.12.3 Current & Previous sessions .........41 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...
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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 fi tted, with a maximum of 17 feed trays. Its sophisticated software control optimises the order and fl ow of documents for collating at the insert head before insertion into the envelope. -
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 machine, with suffi... -
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 be checked • When the mains cable or plug is worn or damaged. • When water or other liquid has entered the device. by the •... - 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.
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Page 8: Technical Specification
TECHNICAL SPECIFICATION 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. -
Page 10: Parts Identifi Cation
Parts identifi cation Daily post tray PC control panel Tower feeder Tower folder Standard feeder (see below) Insert/collate area Envelope hopper Note: Station 1 is the fi rst Filled feed unit after the insert/ envelope tray collate area. Storage cupboards (PC under insert head) Feed trays (either 3 or 1) 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, confi... -
Page 12: Starting The Operating Program
Starting When you fi rst 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 confi... -
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 Confi guration (authorised personnel only). explained Exit to setup Current time Machine Exit software... -
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 fi ne tuning for unit and hopper. Inserter settings Unit Fine Tuning Click on the envelope inserter on the machine graphic to display the fi ne tuning screen. - 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.
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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 fi ne tuning for unit(shown here) and hopper (shown overleaf). Inserter The settings available will vary between feeders settings and folders. Click on the feeder or folder on the machine graphic to display the fi... - 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.
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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 defi... -
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. - 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.
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Page 23: The Barcode/Label Screen
5.6 The Barcode/Label screen 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. - 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 fi...
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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 setup... - 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. (contd.) the ‘Computed’ button to uncheck the box, and then click the ‘True Weight’ button.
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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 the setup... - 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. (contd.) weight, click the ‘Computed’ button to uncheck the box, and then click the ‘True Weight’...
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Page 29: The Confi Guration Screen
The Confi guration screen From this screen you edit confi gurations that were created in the List Box after clicking the ‘Confi guration’ button in the Setup screen (see page 19) or click on ‘New’ if creating a new confi guration. A confi guration applies the settings to be used for the envelope inserter and all the stations fi... -
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.
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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 confi guration screen is selected. This section allows you to set up batching on the output conveyor the output (where fi tted). Note: This screen will only be available to options personnel with Supervisor access. -
Page 36: Setting The Postage Options
5.9.7 Setting Ensure that the Postage tab in the confi guration screen is selected. This section allows you to defi ne weight groups for setting different the postage postage rates. The fi lled envelopes can then be diverted to different options locations, according to the weight range that they fall within. -
Page 37: Setting The Miscellaneous Options
5.9.8 Ensure that the Miscellaneous tab in the confi guration 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 confi... -
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 fi... -
Page 41: View Summary
5.12.2 View Press the ‘Summary’ button to view the fi ltered data. Note that only valid events will be shown, ie. those that involved documents being fed Summary (a machine confi guration 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 fi... -
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 undefi ned). These are text fi les and are named according to their type, followed by the jobname and date (see example below). -
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 fi nished defi ning a confi guration, it can be associated with a Job. Click on Job in the Setup screen and select the confi guration confi guration, as described in the ‘The Job Screen’ on page 38. Running the When you have associated the confi... -
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 Specifi... -
Page 46: Setting Up The Machine
SETTING UP THE MACHINE Loading the paper hoppers Pull the weighted roller back and load the inserts, ensuring they are fully down. Insert Feeder (Single, tower, OMR/ 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 fi tted with a 2-position stop that can be raised or lowered. 1. -
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 fi... -
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 suffi... -
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.
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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.
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Page 56: Maintaining The Wetting System
Maintaining the wetting system The wetter tank supplies the fl uid for wetting the envelope fl aps 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. -
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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Page 59: General Specifications
GENERAL SPECIFICATIONS This document covers specifi cations for general data (form and insert sizes, envelope speci- fi cation and physical and electrical data). Separate specifi cation documents are also avail- able for Barcode Labels and OMR Marks. Please note that stationery sizes and weights are stated as a guide; specifi c applications may use stationery of a fi... -
Page 60: Form Sizes
11.1 Form Sizes Tower Folder Depth: 140mm (5 ”) min. 406mm (16”) max. Width: 140mm (5 ”) min. (Widths below 168mm (6.6”) require narrow fi nger kit A3348A). 229mm (9”) max. Thickness: 60gsm (16lbs bond) min. 70gsm (18lbs bond) min. for OMR/Barcode paper 120gsm (32lbs bond) max. - Page 61 Feeder Folder Depth: 140mm (5 ”) min. (89mm (3½”) for shortforms*) 406mm (16”) max. (139mm (5½”) for shortforms*) * Optional Shortform kit A3302A must be fi tted if short- forms are being used. Width: 140mm (5 ”) min. (Widths below 168mm (6.6”) require narrow fi...
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Page 62: Insert Feeder Unit
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 fi nger kit A3348A). 241mm (9 ”) max. -
Page 63: Envelope Specifi Cation
11.3 Envelope Specifi cation Min. 10mm Minimum open ") Flap Length throat area Max.50mm( 2") Min. Flap Shoulder Angle Throat angle Min.32mm(1 ") 10mm 50° Min. 90° Max. 5° Min. 20° Max. ") Body Depth Min.70mm (2 ") Throat Depth Max.165mm (6 ") Max.22mm (... - Page 64 Envelope requirements (cont.) No twisting, curling or distortion evident. No glue seepage on interior or exterior of envelope. Paper smoothness: 100-200 Sheffi eld 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.
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Page 65: Mechanical & Electrical
11.4 Mechanical & Electrical Speed: Variable up to: 4500 (3750 for SE versions) fi lled 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). - Page 66 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 sunlight b) Protect the machine from direct sunlight using blinds or similar blocking devices.
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Page 67: Machine Dimensions
11.5 Machine Dimensions Notes 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 suffi cient space at paper trays to enable comfortable loading and access for tray removal. If moving the machine, ensure the wheel brakes are off and push on the stand, not the machine. -
Page 68: High Capacity Conveyor Belt Cs-2 (Optional)
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: • The belt moves continuously. • The belt moves in intervals. The belt moves each time a sensor detects the passage of an envelope.
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