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Opex STS Falcon Operator's Manual

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Front Cover
October 2022
STS™ Operator Manual
9296900OM-EN
Revision 22-01
Original Instructions
STS™
WARNING
Read this manual thoroughly before attempting to operate or service this
equipment. Keep a current copy for your reference.
®
© 2019, 2021, 2022 OPEX
Corporation
All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion
of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its
intended
use without the express, written consent of OPEX
Corporation.

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Summary of Contents for Opex STS Falcon

  • Page 1 © 2019, 2021, 2022 OPEX Corporation All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its...
  • Page 2 Fax: +1 856.727.1955 https://www.opex.com/ If you find errors, inaccuracies, or any other issues or concerns with this document, please contact the OPEX Technical Writers via email at: GroupDMATechWriters@opex.com For help with opexservice.com website-related issues, please contact the OPEX Web Developers via email at: dshelp@opex.com...
  • Page 3 I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s) and Standard(s). Place: Moorestown, New Jersey USA (Signature) Date: August 26, 2016 H. Scott Maurer (Full Name) President, OPEX International (Position) Contacting OPEX STS™ Operator Manual OPEX Corporation...
  • Page 4 Ref. Certif. No. US/6554/ITS-M1 IEC SYSTEM FOR MUTUAL RECOGNITION OF TEST CERTIFICATES FOR ELECTRICAL EQUIPMENT (IECEE) CB SCHEME Contacting OPEX STS™ Operator Manual OPEX Corporation...
  • Page 5 - added section on proper care for ink 21-01 July 2021 cartridge page 67 - streamlined glossary to only include terms mentioned in manual Page 69 - updated “About OPEX Corporation” text A few spelling/grammatical corrections. October 13, Page 2 - updated contact information 22-01 2022 Page...

  • Page 6: Table Of Contents

    2.4. Other Workflows ................... 32 2.4.1. Insurance Blacklisting ..............32 2.4.2. Return Mail Processing ..............32 2.5. Main Components ................. 33 Chapter 3 Operation 3.1. Overview ....................40 3.2. Powering Up ..................40 Table of Contents STS™ Operator Manual OPEX Corporation...
  • Page 7 5.1.4. Bin Specifications ................63 5.1.5. Printing Specifications ..............64 5.1.6. Environmental Specifications ............64 5.2. Equipment layout and required floor space .......... 65 5.3. Contacting OPEX Service ..............66 Chapter G Glossary G.1. List of Terms ..................68 Table of Contents STS™...
  • Page 8 (This page intentionally blank) Table of Contents STS™ Operator Manual OPEX Corporation...
  • Page 9 1. Safety 1.1. Introduction ......... . . 10 1.2.

  • Page 10: Safety

    1.1. Introduction The information provided in this chapter is intended to educate you on various safety issues regarding the operation and maintenance of the OPEX equipment described in this manual. This chapter provides an explanation of the safety conventions used throughout this manual, as well as safety guidelines to be observed when working with this equipment.

  • Page 11: Safety Conventions Used In This Manual

    Indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. NOTICE Indicates information considered important, but not hazard related (e.g. messages relating to property damage). Safety STS™ Operator Manual OPEX Corporation...

  • Page 12: Safety Guidelines

    - Do not modify the design or configuration of the equipment Machine design without consulting OPEX or your authorized representative. Machine Maintenance - Machine maintenance, particular operations, and all adjustments, whether mechanical or electrical, shall be carried out by persons authorized to do so in accordance with a safe system of work.

  • Page 13: Consignes De Sécurité - Traduction Française

    Ne pas faire preuve de prudence peut entraîner un choc électrique ou la mort. Conception de la machine - Ne modifiez pas la conception ou la configuration de l'équipement sans consulter OPEX ou votre représentant autorisé. Safety STS™ Operator Manual OPEX Corporation...
  • Page 14 - La prise doit être installée à proximité de l'équipement et doit être facilement accessible. Tenir à l'écart des enfants - Cet équipement ne convient pas aux endroits où les enfants sont susceptibles d'être présents. Safety STS™ Operator Manual OPEX Corporation...

  • Page 15: Safety Labels

    Although they appear different, the locations of these labels are identical. CAUTION Follow the safety precautions described by these labels to avoid injury when operating the STS. Failure to follow these precautions may result in severe personal injury or damage to the machine. Safety STS™ Operator Manual OPEX Corporation...
  • Page 16 1.5.0.1. E-Stop ring label Location: Front of machine in two locations (Table 1-1). Purpose: Draws attention to location of Emergency Stop button. Table 1-1: E-Stop Ring label Label location Description All (8156400) Safety STS™ Operator Manual OPEX Corporation...
  • Page 17 The moving parts of the STS can become jammed and/or damaged by foreign objects (Figure 1-1). The tangle warning label appears next to each E-Stop switch. Figure 1-1: Tangle label Safety STS™ Operator Manual OPEX Corporation...
  • Page 18 1.5.0.3. Ratings / Serial Number label Location: Back of machine (Table 1-2). Purpose: Identifies product electrical ratings, machine serial number, CE logo. Table 1-2: Ratings/Serial Number label Label location Description US (8189200) EU (8189300) Safety STS™ Operator Manual OPEX Corporation...

  • Page 19: Emergency Stops

    (E-stop) switches shown in Figure 1-2. These E-stops can be used to stop the machine in an emergency situation. Note: E-Stops should not be used for normal stopping. For more on proper operations of the machine, refer to “Operation” on page Figure 1-2: STS E-Stop locations Safety STS™ Operator Manual OPEX Corporation...

  • Page 20: Ergonomics

    95% of the user population. Operation by individuals with limited reach capability or who cannot follow the suggestions listed should be avoided or limited in duration. To reduce possible risks, we strongly urge you to follow these suggestions: Safety STS™ Operator Manual OPEX Corporation...
  • Page 21 STS and Falcon series scanner if you put these suggestions into practice. This system has been designed with you in mind. If it is operated correctly, you should find your work experience comfortable and enjoyable. Safety STS™ Operator Manual OPEX Corporation...
  • Page 22 (This page is intentionally blank) Safety STS™ Operator Manual OPEX Corporation...

  • Page 23: Introduction

    2. Introduction 2.1. Overview ..........24 2.1.1.

  • Page 24: Overview

    2.1. Overview The OPEX® STS™ is the latest addition to OPEX Corporation’s Falcon series one-step document scanning workstations. And with a Rapid Extraction Desk (RED), it can address the needs of today’s digital mail rooms. The STS, when combined with a Falcon* series scanner, allows for mail rooms to Sort envelopes, Track items, and Scan content based on the end-user’s decisions.

  • Page 25: Envelope Extraction / Content Scanning

    5. STS sorts mail to individual bins based on the end-user or company’s authorization. 2.1.2. Envelope Extraction / Content Scanning Using the OPEX Falcon RED, authorized “open & scan” envelopes can be opened and contents scanned in a single step. Digital content is now available for delivery to the end-user’s email.

  • Page 26: Workflow - Pass 1

    Note: The maximum envelope thickness specification for the STS is 0.188” (0.477 cm) 3. The Falcon-series imagers locate an area to print on the envelope. 4. The print head prints the barcode and the human readable text. Introduction STS™ Operator Manual OPEX Corporation...

  • Page 27: More On The Pass 1 Job

    0.8” height by 2” long, located a minimum of 0.5” from the lead edge, a minimum of 3” from the outboard edge, a minimum of 0.5” from the inboard edge, and a minimum of 1” from the trail edge (example in Figure 2-2). OPEX Corporation Inboard Edge 1224 N Church St Moorestown, NJ 08057 0.5”...

  • Page 28: Workflow - Pass 2

    Then, co-mingling decisions in some bins may be necessary. Mail that has no decision, will not be printed and will be sorted to a designated bin. This bin will be reprocessed at a later time. Introduction STS™ Operator Manual OPEX Corporation...
  • Page 29 Bin 4 below. 7. Completed batch is sent to the back-end software. Batch includes bin ID(s) of source and destination bins, along with the counts expected for each bin. Introduction STS™ Operator Manual OPEX Corporation...

  • Page 30: More On The Pass 2 Job

    • Forwarded pieces can have instructions printed via audit trail and can optionally be sorted to the reject bin, the deliver bin, or any bin the customer designates. Introduction STS™ Operator Manual OPEX Corporation...
  • Page 31 • The idea for each pass is to run as quickly as possible, reject/out-sort any exceptions, re-run those and use on screen messages to resolve any errors; then close the completed batch, which is generally comprised of pieces from one source bin. Introduction STS™ Operator Manual OPEX Corporation...

  • Page 32: Other Workflows

    3. It would be possible, in a second pass to determine which mail might need to be opened, or the database corrections needed to fix the issue. In this application, the idea would be to not open as much mail as possible. Introduction STS™ Operator Manual OPEX Corporation...

  • Page 33: Main Components

    2.5. Main Components This section describes the main components of the STS system. Conveyor - a series of rollers that sends the mail down the machine for further processing (Figure 2-4). Figure 2-4: Conveyor Introduction STS™ Operator Manual OPEX Corporation...
  • Page 34 - As an envelope moves underneath this assembly, the wheel forces it against the front wall, so that the printing of barcode information will be in the optimal location (Figure 2-5). Figure 2-5: Justifier Introduction STS™ Operator Manual OPEX Corporation...
  • Page 35 The printer cover, shown in the open position in Figure 2-6, has an interlock switch that cuts the power to the printer boards when the cover is open. This prevents damaging the printer boards when the ink cartridge needs to be replaced. Figure 2-6: Printer Introduction STS™ Operator Manual OPEX Corporation...
  • Page 36 All four pop-up belts rise to sort a piece into the destination bin (Figure 2-7). Gate Assembly (rollers removed) Gate Assembly for Bin 3 engaged Figure 2-7: Pop up gates Introduction STS™ Operator Manual OPEX Corporation...
  • Page 37 Reject Tray Bin 1 Bin 2 Bin 3 Bin 4 Figure 2-8: Bin locations Introduction STS™ Operator Manual OPEX Corporation...
  • Page 38 (This page intentionally blank) Introduction STS™ Operator Manual OPEX Corporation...

  • Page 39: Operation

    3. Operation 3.1. Overview ..........40 3.2.

  • Page 40: Overview

    1. If the STS system is not already up and running, make sure the printer door is closed, and turn on the power. The power switch is located on the back of the machine close to the Falcon (Figure 3-1). Figure 3-1: STS power switch Operation STS™ Operator Manual OPEX Corporation...
  • Page 41 If your Falcon is not connected to a network, you may not have to log in to Windows first. Once the computer has finished booting Windows, it will launch the Falcon CertainScan application. Operation STS™ Operator Manual OPEX Corporation...
  • Page 42 Note: If you do not have your own user account, ask your Falcon Adminis- trator for assistance. Select a user account icon Enter password Press OK Figure 3-4: Login Screen 2. Enter your password using the on-screen or computer keyboard. 3. Press OK. Operation STS™ Operator Manual OPEX Corporation...

  • Page 43: Navigating The Falcon Certainscan Software

    CertainScan software. The list of menus presented is determined by the user’s account-level permissions. Title bar Menu bar Main window Menu options Figure 3-5: Menu Select window Operation STS™ Operator Manual OPEX Corporation...
  • Page 44 Windows functions (Restore, Move, Size, Minimize, Maximize, Close), as well as the following menus: • The diagnostics menu is reserved for OPEX technicians. • The Help menu accesses the About screen, which provides version information for the Falcon CertainScan software.

  • Page 45: Running Jobs

    Depending on how the job is set up, you will either see the Run screen (see Figure 3-7), the Modify Batch Information screen, or a prompt in which the operator can enter a custom batch name, as described in the “CertainScan 4.0 Software Manual.” Operation STS™ Operator Manual OPEX Corporation...

  • Page 46: Using The Run Screen

    They can rearrange the information and preview windows to best suit their job requirements. For more information on how to use the CertainScan software, please refer to the “CertainScan 4.0 (or higher) Software Manual.” The current CertainScan Software Manual can be downloaded at: https://www.opexservice.com/ Operation STS™ Operator Manual OPEX Corporation...

  • Page 47: Scanning Mail

    Note: The scanner may also reject items that are misfed, skewed, or because the item was not properly identified. In these cases, the scanner will stop after all the items in the track have been sent to the reject bin. Operation STS™ Operator Manual OPEX Corporation...
  • Page 48 (This page is intentionally blank) Operation STS™ Operator Manual OPEX Corporation...

  • Page 49: Maintenance

    4. Maintenance 4.1. Cleaning the System........50 4.1.1.

  • Page 50: Cleaning The System

    When the print head clogs, the quality of the printed image suffers as ink fails to reach the envelope, leaving horizontal white lines where the ink jets have clogged. If the printer doesn't get cleaned when it first clogs, the ink can Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 51 1. If not in use for more than an hour, cap the ink cartridge with provided cap. If not in use for more than 24 hours, cap and bag the cartridge (Figure 4-1). CAPPED Figure 4-1: Capped and bagged ink cartridges Maintenance STS™ Operator Manual OPEX Corporation...

  • Page 52: Purging The Printer

    2. If this process has not been completed, you can use an Isopropyl Alcohol wipe to clean the heads. This will help rejuvenate the head from being dried out. An OPEX MIT Inkjet Swab (1999300) is shown in Figure 4-2. Figure 4-2: Scrub Print Heads 3.
  • Page 53 2. On the run screen, click on the Printer tab in the lower right area. If the Printer tab does not appear, right-click on the blue bar and select Printer from the list (Figure 4-3). Figure 4-3: Item Properties - Selecting Printer Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 54 3. The Printer tab displays the nozzle status and ink level for the STS Printer. Click anywhere in this area to bring up the Printer window (Figure 4-4). Figure 4-4: Printer window Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 55 6. Press the Purge button in CertainScan (on the Falcon’s screen). It will spit out some ink to prime the print head for proper use. 7. Move the envelope and press the Purge button a second time. Maintenance STS™ Operator Manual OPEX Corporation...

  • Page 56: Cleaning The Printer Head

    4.2.2. Cleaning the printer head Cleaning the printer is a three-step process, described on the following pages: 1. Remove the cartridge (page 2. Clean the print head (page 3. Reinsert the cartridge (page Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 57 Figure 4-7: Lift cover to access printer TIP: If the printer assembly is towards the back as shown in Figure 4-7, you can manually slide the assembly forward to make it easier for the next steps. Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 58 2. Use a lint free cloth or lint free swab (1999300 for a bag of 50) dipped in isopropyl alcohol to scrub the print heads (Figure 4-9). Do not use water or other cleaners, as they will damage the head. Figure 4-9: Scrub print heads Maintenance STS™ Operator Manual OPEX Corporation...

  • Page 59: Installing A New Printer Cartridge

    6. Lower the green lever to lock it in place. 7. Close the printer cover which will restore power back to printer. 8. Once the cartridge is installed, it is recommended to purge the printer, as described in “Purging the printer” on page Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 60 (This page intentionally blank) Maintenance STS™ Operator Manual OPEX Corporation...
  • Page 61 5.2. Equipment layout and required floor space....65 5.3. Contacting OPEX Service ....... 66 STS™...

  • Page 62: Specifications

    5.25” to 15” (12.7cm to 38.1cm) Width 4.25” to 12” (10.795cm to 30.48cm) Thickness Up to 0.188” (0.4775cm) Type Coated, uncoated and gloss substrates (no PVC, Tyvek) Curl height Less than 0.25” (0.64cm) on lead edge Specifications STS™ Operator Manual OPEX Corporation...

  • Page 63: Operational Specifications

    • Operator removable from front of machine • Size: 15"W x 17"L x 1.5"H (centimeters = 38.1W x 43.18L x 3.81H) Reject Pocket Specs • Volume: 0.22 cubic feet (0.006 cubic meter) (Approximately 15, #10 envelopes) Specifications STS™ Operator Manual OPEX Corporation...

  • Page 64: Printing Specifications

    L (12.7mm H x 38.1mm L) 5.1.6. Environmental Specifications Agency approvals UL, CE, ROHS/REACH Sound level < 80 dB in operating mode Operating, Transportation and 15 - 35°C (59 - 95°F) Storage Temperatures Humidity 15-76% RH Specifications STS™ Operator Manual OPEX Corporation...

  • Page 65: Equipment Layout And Required Floor Space

    1. All dimensions are approximate and are provided for reference only. 2. Allow for at least 36” (91.44 cm) walking/working space around the front, back and left side of machine (right side is the Falcon location). Specifications STS™ Operator Manual OPEX Corporation...

  • Page 66: Contacting Opex Service

    5.3. Contacting OPEX Service Before contacting OPEX Technical Support, the Authorized Employee should locate the Service Tag on the back of the machine so that they can provide the assisting OPEX technical support representative with the machine serial number (Figure 5-2).

  • Page 67: Chapter G Glossary

    G. Glossary G.1. List of Terms......... . 68 STS™...

  • Page 68: List Of Terms

    Transaction Sorting - A term used to indicate jobs in which prior items within a transaction/set determine the sorting of later items. Glossary STS™ Operator Manual OPEX Corporation...
  • Page 69 About OPEX Corporation OPEX Corporation is more than a manufacturer of machines. We continuously reimagine technology to power the future for our customers. With an innovative approach, we engineer unique automated solutions that support our customers so they can solve the most pressing business challenges for both today and tomorrow.
  • Page 70 OPEX Corporation | 305 Commerce Drive | Moorestown, NJ 08057-4234 | USA http://www.opex.com...

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