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4.

Slide the spring loaded collar of the pickup roller assembly inwards to release the

drive dog as shown below.

5.

Remove the pickup roller and replace as required, ensuring the drive dog is fully

engaged when replaced.

6.

Lower the collate clam back down into it’s original position, and close the Insert

Head Perspex top cover once replacement is complete.

Versatile Feeder Feed Tyres

1.

Unscrew and remove the three thumb screw knobs in the feed hopper as indicated

below.

2.

Open the side guides to their widest extent.

182

| Page 182 | May-29-2020 11:33 |

6

Operator

Maintenance

Summary of Contents for DS-200iQ

Page 1: ...ergrated Mail Operating System IMOS 21 3 3 1 IMOS Control Panel 23 3 2 Menu Screen 25 3 3 Jobs Screen 46 3 4 Run Screen 47 3 5 Help Menu 57 3 6 Users Screen 59 3 7 IMOS F Keys 62 Operator IMOS Settings 69 4 4 1 Creating a Job 71 4 2 Define Mailset 72 4 3 Place Mailset 85 4 4 Fold Settings 86 4 5 Mail Sorting 91 4 6 Output Placement 96 4 7 Output Settings 97 4 8 Saving the Job 106 Operator Instruct...

Page 2: ...er Troubleshooting 195 7 4 Flex Folder Troubleshooting 196 7 5 Output Conveyor Troubleshooting 197 7 6 Output Sorter Turner Troubleshooting 198 Technical Specifications 199 8 8 1 General Specifications 201 8 2 Insert Head Specifications 206 8 3 Versatile Feeder Specifications 215 8 4 Flex Folder Specifications 217 8 5 Output Conveyor Specifications 221 8 6 Output Sorter Turner Specifications 222 8...

Page 3: ...rious bodily injury Ensure all safety information detailed in section Safety on page 5 including it s sub sections are read and understood in it s entirety before installation operation maintenance and or servicing of this machine 1 1 About this Manual 3 1 2 Standards and Compliance 4 1 3 Safety 5 1 Page 1 Safety Standards Compliance May 29 2020 11 33 ...

Page 4: ......

Page 5: ...bility for a particular application This guide is published without any warranty Improvements and changes to the online guide if applicable necessitated by typographical errors inaccuracies of current information or improvements to programs and or equipment may be made at any time and without notice Such changes will however be incorporated into new editions of the PDF version of this guide if app...

Page 6: ...t 15B Class A Federal Communications Commission FCC in all states and territories of the United States Applicable Directives Low Voltage Directive 2014 35 EU Electromagnetic Compatibility Directive 2014 30 EU The product presented in this guide meets the requirements of applicable directives All machines are built to strict safety specifications in accordance with UL Standards Low Voltage Directiv...

Page 7: ...o the user and others and to prevent property damage The meanings of these symbols are described in section Safety Symbols on page 5 and is important these symbols are observed and their descriptions read thoroughly to understand their meanings Prior to carrying out any installation operation maintenance or servicing procedures on this machine ensure you have fully observed and understood all safe...

Page 8: ... ratings where possible before replacing Caution Warning Indicates a situation in which minor moderate or serious injury could occur because of the hazard present Important Note Refers to the important note referenced detailed within the manual Refer to Manual Refers to the relevant instructions referenced detailed within the manual 6 Page 6 May 29 2020 11 33 1 Safety Standards Compliance ...

Page 9: ...thing or jewellery and long hair must be tied back or tucked under a hat when working near the machine as they may become caught in any one of the moving parts resulting in injury Before any cleaning maintenance and or servicing the machine must be completely isolated from the power source by pressing the toggle switch located at the rear of the Insert Head to the off position and unplugging the m...

Page 10: ...d three prong outlet Do not use a two prong adapter without grounding the machine properly The machine must be earthed Never remove the third prong from the plug The safety grounding protective earth feature provides extra protection in the event of an electrical problem The mains power supply is fused on both live and neutral sides Service personnel should be aware that a mains voltage can exist ...

Page 11: ...troduction 2 2 1 General Overview 11 2 2 Functional Overview 12 2 3 Overview of Components 13 2 4 DS 200iQ DS 600iQ Configurations 16 2 5 Powering on the System 18 9 Page 9 Introduction May 29 2020 11 33 ...

Page 12: ......

Page 13: ...as a basic configuration it consists of an Insert Head with a feeding unit fitted such as a Versatile Feeder or a Flex Folder Other configurations may include multiple Versatile Feeder units with output units also fitted such as an Output Conveyor Output Sorter and or Turner 11 Page 11 May 29 2020 11 33 2 Introduction ...

Page 14: ... collated on the track prior to folding The DS 200iQ DS 600iQ is equipped with a PC controlled Integrated Mail Operating System IMOS and is accessed via touch screen monitor or keyboard mouse from where jobs can be programmed and run The number of jobs that can be programmed is limited only by the capacity of the PC A daily mail function can be used as an optional feature on a Versatile Feeder or ...

Page 15: ...nsing conveyor that operates on demand to move the envelope stack forward Collation and Insertion Area Folded forms either separately or in groups are collated here into one pack along with enclosures by the collate pocket The pack is then inserted into the envelope Touch Sensitive Monitor Touch Sensitive Monitor is used to operate and navigate IMOS and responds to button pushes through the Graphi...

Page 16: ...rsatile Feeders It folds documents either separately or in groups using an accumulator and is fitted with various options of feed pods maximum of 2 feed pods Folding including no fold options may be set within IMOS and used for certain job types if required Flex folder uses a 3 plate folding mechanism and 2D BCR OMR reading is fitted as standard though a no read option is also available on some va...

Page 17: ...sted to suit the required amount of tilt Output Sorter Components Output Sorter is an output device and receives mail pieces from an Inserter and directs them to two or more output paths e g an Output Conveyor Operation of the Output Sorter is programmed within IMOS and is job specific Sorter Catch Tray Sorter Catch Tray is optionally fitted at either exit of the Output Sorter and receives the env...

Page 18: ...e following units installed Insert Head Versatile Feeder 2 x units Flex Folder up to 2 feed pods accumulator and divert tray Output Conveyor 2 x units Output Sorter 2 x units sorter catch tray Turner Franking Machine For further information regarding the possible configurations for the DS 200iQ DS 600iQ please contact your local Manufacturer Customer Support representative 16 Page 16 May 29 2020 1...

Page 19: ...2 Introduction 17 Page 17 May 29 2020 11 33 ...

Page 20: ...the machine and PC must be switched on independent of each other 1 To power on the machine first press the I O toggle switch at the rear bottom right panel of the Insert Head as shown below 18 Page 18 May 29 2020 11 33 2 Introduction ...

Page 21: ...board below the Insert Head to access the PC and press the I O button on the PC to power it on The system can be set to automatically power down after 60 minutes of idling no activity see section System Options on page 44 for further assistance Pushing and holding down the front I O power button for one second will power down both the machine and PC 2 Introduction 19 Page 19 May 29 2020 11 33 ...

Page 22: ......

Page 23: ...File 34 Diagnostics 38 3 3 Jobs Screen 46 3 4 Run Screen 47 Job Count Settings 54 Batch Count Settings 55 Present at Exit 50 Finger Sequence 51 Envelope Stop Position 52 Finger Adjust 54 3 5 Help Menu 57 Remote Assistant 58 3 6 Users Screen 59 Switching Users 60 3 7 IMOS F Keys 62 F1 Key 63 F2 Key 63 F3 Key 64 F4 Key 65 21 Page 21 Intergrated Mail Operating System IMOS May 29 2020 11 33 ...

Page 24: ...F5 Key 65 F6 Key 66 F7 Key 66 F8 Key 67 F9 Key 67 22 Page 22 Intergrated Mail Operating System IMOS May 29 2020 11 33 ...

Page 25: ...o setting up and running jobs Menu screen Libraries for storing creating new documents envelopes barcodes and labels reading definitions and postal products etc Admin and Engineer services for hardware and unit set ups and diagnostics Access to the Menu screen is only available once logged in as a Supervisor or Engineer 23 Page 23 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 26: ...ing a job Fine tuning a job Help Help and Remote assistance Users Shut down Log on log off and switching users Changing user password Shut down machine Correct access rights must be granted before gaining access to certain functions of IMOS 24 Page 24 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 27: ... top right of the control panel as indicated below Access to the Menu screen is only available once logged in as a Supervisor or Engineer Access to Admin Settings is only available once logged in as a Supervisor 25 Page 25 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 28: ...created it will then be added to the list of definitions to be used for mailsets The example below shows the list of documents defined and available for use with options for copying and editing or creating a new definition Definitions can also be sorted by name date created and by specific filters applied for easy finding of a previously created definition Both Supervisors and Engineers can copy e...

Page 29: ...or documents when defining a mailset contact your local Support Engineer Documents Library To create new Documents to be used when defining a mailset see section Creating a New Document on page 81 for further assistance Envelopes Library To create new Envelopes to be used when defining a mailset see section Creating a New Envelope on page 75 for further assistance Postal Products Library To create...

Page 30: ...rvices within the Menu screen as shown below Admin settings allow access to the following functions and settings System Security Level Archive Data Languages Machine Id Machine Name Generate Licence File Licenced Features Imported Files 28 Page 28 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 31: ...ity level select a level from the list and press Ok once complete as shown below Table below shows the security level options available and an example list of certain operations and features available to each associated security level 3 Intergrated Mail Operating System IMOS 29 Page 29 May 29 2020 11 33 ...

Page 32: ...Admin services within the Menu screen and browse for a folder in the dialog box press Ok once complete as shown below The USB key supplied with the machine plugged into the PC at all times can also be used as the backup location allowing the data to be stored remotely off the PC hard drive It is recommended to archive data on a regular basis 30 Page 30 May 29 2020 11 33 3 Intergrated Mail Operatin...

Page 33: ...ich language IMOS will display when operating or servicing the machine 1 To set a language select an available language from the list and press Ok once complete as shown below 3 Intergrated Mail Operating System IMOS 31 Page 31 May 29 2020 11 33 ...

Page 34: ...er to assign a Id for the machine using the on screen keypad as shown below press Ok once complete Multiple machines on the same site should have different Machine ID s 32 Page 32 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 35: ...ame for the machine using the on screen keypad as shown below press Ok once complete Multiple machines on the same site should have different Machine Name s and must not contain any spaces 3 Intergrated Mail Operating System IMOS 33 Page 33 May 29 2020 11 33 ...

Page 36: ...ration of a blank Licence_IMOS ini file to be used for upgrading by your local support service team and will erase any existing licences on the machine 1 Press Ok once complete as shown below 34 Page 34 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 37: ... licenced and unlicenced if applicable on the machine as shown below See section Reading Specifications on page 224 for further information regarding the reading licencing of Barcodes and OMR marks 3 Intergrated Mail Operating System IMOS 35 Page 35 May 29 2020 11 33 ...

Page 38: ...ays details of Custom Flex_barcodes imported into IMOS as shown below Details are not shown if there are no files imported or if no Flexbarcode licence on the machine 36 Page 36 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 39: ... within the Menu screen as shown below Supervisor Service settings allow access to the following functions and settings Diagnostics System Options You must be logged in as an Engineer to obtain full access to all available Service options 3 Intergrated Mail Operating System IMOS 37 Page 37 May 29 2020 11 33 ...

Page 40: ...list of services then select the Analog sensors tab at the top of the diagnostics screen 2 Select the required unit needing sensor calibration and press Ok once complete as shown below 3 Analog sensors can be calibrated individually or together by pressing the Cal All Paper sensors button in the bottom right corner of the screen 4 Press Exit once the desired settings have been made 38 Page 38 May ...

Page 41: ...ple of a typical analog sensor value and translates as follows T Threshold voltage generally over 2 5V this is the switching voltage between blocked and clear I Effort of current required to read across the sensor halves typically between 10 and 60 R Percentage of pot value on PCB C clear B blocked and sensor voltage typically 0 5V for clear 4 5V for blocked 3 Intergrated Mail Operating System IMO...

Page 42: ...ge below shows typical analog sensor values for the Insert Head Wetter fluid sensor will always show a typical value above 4 5V Blocked because it is detecting fluid 40 Page 40 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 43: ...Versatile Feeder Analog sensors The image below shows typical analog sensor values for the Versatile Feeder 3 Intergrated Mail Operating System IMOS 41 Page 41 May 29 2020 11 33 ...

Page 44: ...Flex Folder Analog sensors The image below shows typical analog sensor values for the Flex Folder 42 Page 42 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 45: ...Output Sorter Analog sensors The image below shows typical analog sensor values for the Output Sorter 3 Intergrated Mail Operating System IMOS 43 Page 43 May 29 2020 11 33 ...

Page 46: ...chine and PC will be set to automatically power down after 60 minutes of idling no activity and when in an auto ended state Allow Custom fold selection No Yes If Yes is selected Custom Fold options will then be enabled and available for use within the Fold settings when creating a new job see section Fold Settings on page 86 for further assistance CAN Type 44 Page 44 May 29 2020 11 33 3 Intergrate...

Page 47: ...Controller Area Network CAN interface device to be used Remote Assistant Path Sets the path to be used when accessing Remote Assistant Press Ok once complete as shown below 3 Intergrated Mail Operating System IMOS 45 Page 45 May 29 2020 11 33 ...

Page 48: ... button in the IMOS control panel The Jobs screen allows the user to select a job to run create a new job copy edit or delete an existing job from the jobs list See section Running a Job on page 150 to run an existing job directly from the list of the IMOS Jobs screen 46 Page 46 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 49: ...The Run screen is displayed once a job has been accepted in the Jobs screen or by pressing the Run button in the IMOS control panel indicated below 47 Page 47 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 50: ...ob press the or to increase or decrease the speed Job Count indicator Job Count indicator indicates the current job count and total job count of the current job press anywhere inside the job count area to adjust the count settings see section Job Count Settings on page 54 for further information Batch Count indicator Batch Count indicator indicates the current batch count and total count of the cu...

Page 51: ...ingle Cycle button on the Run screen These options allow various adjustments to be made before beginning the job in order to minimise insertion crashes If the current job is programmed with AIMS only Present at Exit will be enabled 3 Intergrated Mail Operating System IMOS 49 Page 49 May 29 2020 11 33 ...

Page 52: ... check the address alignment 1 After pressing Present at exit the first mail piece will be processed and the machine will stop to allow the operator to adjust the vertical alignment of the address 2 Remove the filled envelope and adjust as necessary following the procedure as shown below 50 Page 50 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 53: ...n This allows the operator to set the order of the insertion fingers in the envelope as demonstrated below Make any adjustments as necessary by following the procedure below 1 Open the operator side cover to view the fingers 3 Intergrated Mail Operating System IMOS 51 Page 51 May 29 2020 11 33 ...

Page 54: ...ess Revert to revert back to the original Outers first default finger sequence setting 5 Press Exit once the desired settings have been made Envelope Stop Position After pressing Envelope stop position the machine will feed an envelope into position This allows the operator to adjust the stop position of the envelope at insert as demonstrated below 52 Page 52 May 29 2020 11 33 3 Intergrated Mail O...

Page 55: ... the or button to adjust the position Moves the envelope further into insert position 2 If required press Revert to revert back to the default setting 3 Press Exit once the desired settings have been made 3 Intergrated Mail Operating System IMOS 53 Page 53 May 29 2020 11 33 ...

Page 56: ...ssary by following the procedure below 1 Use the or button to adjust the width of the outer fingers 2 If required press Revert to revert back to the default setting 3 Press Exit once the desired settings have been made Job Count Settings Pressing the Job Count button from the Run screen will display the Job Count settings as shown below 54 Page 54 May 29 2020 11 33 3 Intergrated Mail Operating Sys...

Page 57: ...e job If the job count total is set at 0 the machine will run without stopping 3 Press Ok once the desired settings have been made Batch Count Settings Pressing the Batch Count button from the Run screen will display the Batch Count settings as shown below 1 Firstly set the exit used for batching if required Exits 2 3 appear only if Sorters are fitted 3 Intergrated Mail Operating System IMOS 55 Pa...

Page 58: ...ll display until the job has been changed even if the machine has been switched off and back on again 4 Press the Reset button to zero the current count if required 5 Press Change total to set the total for the job The total batch count number applies only to the selected exit e g Exit 3 6 Press Visible Batch Count to set which exit is used for displaying the batch count on the Run screen 7 Press ...

Page 59: ...he Help menu are as follows Help Accesses this user guide for further operator assistance topics Remote Assistant Accesses further assistance via Team Viewer see section Remote Assistant on page 58 for further information About Displays information about the machine software and firmware etc 57 Page 57 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 60: ... from the Help drop down in the IMOS control panel TeamViewer will launch with a unique ID and Password as shown below 2 Communicate the ID and Password to the support engineer and the link will then be formed between the both of you The support engineer will gain full control of the machine s PC to allow fault diagnosis 3 To end the Team Viewer session simply close the Application 58 Page 58 May ...

Page 61: ...Users Screen 3 6 The Users screen is accessed by pressing the Users button in the IMOS control panel indicated below 59 Page 59 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 62: ... the Users screen Available functions and access rights will depend on who you log on as Switching to an Engineer or Supervisor user requires a password The user will log on once a correct password has been entered using the on screen keypad as shown below 60 Page 60 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 63: ... can be allocated to each user as shown in table below Supervisor only has access to Diagnostics for Sensors and System Options within the Service Menu User access rights can be created or modified only if logged in at the appropriate user level Additionally System Security Levels can be set in Admin settings from the Menu screen See section System Security Level on page 29 for further information...

Page 64: ...ding on the user type logged on Access permissions to F Key functions available to each user type is shown in table below F10 F11 and F12 Keys are currently not used for any function on DS 200iQ and DS 600iQ machines 62 Page 62 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 65: ...Key 1 Press F1 to access the machine Operator documentation F2 Key 1 Press F2 to view General Information of the machine as shown below 3 Intergrated Mail Operating System IMOS 63 Page 63 May 29 2020 11 33 ...

Page 66: ... to access the following F3 Key functions as shown below Capture Trace Allows the retrieval of firmware trace data for selected units as shown below 64 Page 64 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 67: ...o show the Batch Jog and Divert counters as shown below F5 Key 1 Press F5 to access the following Engineer and Factory F5 Key functions as shown below 3 Intergrated Mail Operating System IMOS 65 Page 65 May 29 2020 11 33 ...

Page 68: ...ctory R D and Field Technicians as shown below Envelope Only mode is used for diagnostics only F7 Key 1 Press F7 to view Output log information of mail pieces as they reach the output of the machine as shown below 66 Page 66 May 29 2020 11 33 3 Intergrated Mail Operating System IMOS ...

Page 69: ...formation of mail pieces at the input of the machine as shown below F9 Key 1 Press F9 to access Debug information used by Factory R D and Field Technicians as shown below 3 Intergrated Mail Operating System IMOS 67 Page 67 May 29 2020 11 33 ...

Page 70: ......

Page 71: ... Settings 74 Advanced Document Mailset Settings 79 4 3 Place Mailset 85 4 4 Fold Settings 86 Advanced Fold Settings 88 4 5 Mail Sorting 91 Postal Product 91 Mail Sort Settings 93 4 6 Output Placement 96 4 7 Output Settings 97 Turner Output Settings 98 Franker Output Settings 99 Output Conveyor Settings 100 Printer Output Settings 102 4 8 Saving the Job 106 69 Page 69 Operator IMOS Settings May 29 ...

Page 72: ......

Page 73: ...old Settings Mail Sorting Output Placement Output Settings Saving the Job When defining the Document BCR or OMR definitions can be optionally enabled To use a Barcode definition it must exist as part of the defined document mailset see section Creating a New Document on page 81 for further assistance 71 Page 71 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 74: ...Define Mailset 4 2 1 To begin defining the mailset press New in the Jobs screen as shown below 72 Page 72 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 75: ...et press Select to open the Envelopes selection box then select the required envelope from the list and press Ok as shown below 2 If required press Settings to define the envelope usage Seal mode as shown below 4 Operator IMOS Settings 73 Page 73 May 29 2020 11 33 ...

Page 76: ...elope feeding is disabled to allow forms only 5 Press Ok once the desired settings have been made Advanced Envelope Mailset Settings 1 Press Edit Advanced to set the order of documents inserted into the envelope as shown below 2 Select the required order that documents are inserted into the envelope from the list default set to Automatic If the order is set to Manual documents are inserted in the ...

Page 77: ... below 2 Confirm the new envelope creation process by pressing Yes in the confirmation dialog box 3 Enter an envelope name 4 Select an envelope size If the default dimensions change the size will change to Custom Measure envelopes for the required job carefully before changing the size 4 Operator IMOS Settings 75 Page 75 May 29 2020 11 33 ...

Page 78: ...ult is set to 15 Wetting rate number is the quantity of envelopes sealed before the wetter tank is topped up 8 Enter a Max pack thickness as required Max pack thickness 200iQ 6mm 600iQ 10mm 9 Press Save once the desired settings have been made Users with appropriate access rights can also create Envelopes following the same procedures from the Libraries within the Menu Screen 76 Page 76 May 29 202...

Page 79: ...choose a document type from the library then select the required document from the list and press Ok as shown below 2 If required press Settings to define the document usage Form count Cascading and Hopper feed mode as shown below 4 Operator IMOS Settings 77 Page 77 May 29 2020 11 33 ...

Page 80: ... a Flex Folder The selected number e g up to 2 3 or 4 will depend upon machine configuration and also what document enclosure types have been selected for each hopper See section Cascading Job on page 151 for further assistance in running a job enabled for cascading 5 Select the Hopper feed mode from the list Default Automatically feeds from another hopper when this one runs out Daily mail Hand fe...

Page 81: ...Advanced Document Mailset Settings 1 Press Edit Advanced as shown below for advanced document settings 4 Operator IMOS Settings 79 Page 79 May 29 2020 11 33 ...

Page 82: ...able setting for Thickness Doubles Feed Control Mode Feed Always Used for non selective documents Selective Feed Used for reading enabled units Works in conjunction with Select ID Select ID Defines an ID number for a document in accordance with the Select mark in the label This will then feed the document when that mark is read applies to enclosures only Sequence Handling Mode Determines how seque...

Page 83: ... the size will change to Custom 5 Make any other relevant settings as required 6 When entering the paper weight gsm the true weight g will automatically be calculated by default If required deselect Computed and enter an actual Thickness and True weight figure 7 If using BCR or OMR marked documents select a BCR definition or OMR definition from the list as required Reading capabilities are obtaine...

Page 84: ...low to specify the label position Label positions specified in Region of Interest are relative to the top left hand corner of the document Print orientation i e Portrait or Landscape selected within the New Document screen 82 Page 82 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 85: ...ngs 11 Press Ok once the Region of Interest settings are complete 12 If Doc Id mode is to be used select On This reads a label character and compares its string value with the string entered in Doc Id to confirm that the correct document type is used 13 Press Save once the desired settings have been made For further assistance on BCR definitions and OMR definitions see section Reading Specificatio...

Page 86: ... remainder of the setup process for Enclosures is the same as Documents see section Document Mailset on page 77 for further assistance 2 Press Next once the desired settings have been made Creating a New Enclosure The creation process for new Enclosures is the same as new Documents see section Creating a New Document on page 81 for further assistance 84 Page 84 May 29 2020 11 33 4 Operator IMOS Se...

Page 87: ...pecific hoppers 1 To define a document placement select the document to move then select the hopper to assign it to as shown below 2 To revert back to the default settings press Auto place documents 3 Press Next once the desired settings have been made 85 Page 85 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 88: ...ect or incompatible fold types for the defined document enclosure can produce errors and cause the machine to malfunction 2 Press Adjust fold to adjust the fold or to check the fold lengths Adjust Fold disables Address Adjust when the job is running See section Testing the Mailset on page 49 and Present at Exit on page 50 for further assistance 86 Page 86 May 29 2020 11 33 4 Operator IMOS Settings...

Page 89: ...ed in System Options in the Service screen to adjust the fold plate lengths See section Paper and Fold Details on page 219 and Reading Orientations on page 122 for further assistance 4 Press Ok once the desired settings have been made 4 Operator IMOS Settings 87 Page 87 May 29 2020 11 33 ...

Page 90: ...Advanced Fold Settings 1 Press Edit Advanced as shown below for advanced fold settings 88 Page 88 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 91: ...re not available when feeding face up as the address page will not be in the window of the envelope Divert Oversized All groups more than number set in Divert Split Threshold will be diverted Divert Undersized Same applies for groups below the threshold Machine is then stopped job is changed and forms in divert tray are replaced into the document set and the new job is run Divert Split Threshold I...

Page 92: ...ollowing table shows the handling of oversized undersized groups under different circumstances 3 Press Next once the desired Fold settings have been made 90 Page 90 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 93: ...ddition to weight groups an Exit Selection mark or character can be used to differentiate Mail Sorts The image below shows the maximum configuration of 2 sorters and 3 output conveyors Postal Product A Postal Product is a complete filled envelope Different postal products can be programmed to allow sorting for different needs 1 To use Mail sorting select an existing mailsort from the Postal Produc...

Page 94: ...ox as shown below 3 Enter a name for the new Postal product 4 Set the weight groups and postage rate as required The minimum weight of each group is the same as the maximum weight of the previous group as shown below 92 Page 92 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 95: ...ngs A Mail sort is part of the Postal Product and is used to determine how the mail pieces within it are treated when they reach the sorter by using the following sort criteria as shown below Mail pieces with Weight Group criteria use a priority basis to determine the exit sorter 1 Select the Sort Criteria and then the required Mail sort associated with it 4 Operator IMOS Settings 93 Page 93 May 2...

Page 96: ...Mail sort can have a number of combinations of criteria some of which may overlap you can determine which has priority The image above shows Weight Group 2 and Weight Group 3 both using Mail sort 2 It is possible to change the priority so that mail pieces with Weight Group 3 have priority over those in Weight Group 2 instead of the existing priority 94 Page 94 May 29 2020 11 33 4 Operator IMOS Set...

Page 97: ...ch on the scroll arrows as shown below 4 Use the arrow to adjust the sort priority then select the number again to finalise the sort priority 5 Press Next once the desired Mail Sort settings have been made 4 Operator IMOS Settings 95 Page 95 May 29 2020 11 33 ...

Page 98: ...t may be an Output Conveyor or Catch bin 1 To change the output placement select any exit or mail sort as shown below then select the required exit or mail sort to change it 2 To revert back to the default settings press Auto place mail sorts 3 Press Next once the desired settings have been made 96 Page 96 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 99: ... be used for the output setting set batching to Batch On and then press Ok as shown below The Batch mode must also be set with the following options available Stop When the batch quantity is reached the machine will stop until the Run button is pressed to run another batch Continue When the batch quantity is reached the machine will pause for the specified Batch complete pause time and then resume...

Page 100: ...red Batch quantity number 4 Finally if Continue batch mode is selected set the required Batch complete pause time that the machine will pause for Turner Output Settings The following rotate envelope settings are available when an Turner is fitted with a Franking machine 98 Page 98 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 101: ...shown below If Auto is selected and the height of the envelope is programmed below 140mm it forces the envelope to No rotate before franking Franker Output Settings The following Franking control settings are available when a Franking machine is fitted 4 Operator IMOS Settings 99 Page 99 May 29 2020 11 33 ...

Page 102: ...erter and Franking machine Either machine will stop if an error occurs on either machine Pass through Allows every mail piece to pass un franked 1 Select the required Franker control setting from the list of options and then press Ok as shown below 2 Finally select the Franking job from the list e g Current job Output Conveyor Settings The following Output Conveyor settings are available 100 Page ...

Page 103: ...ts the gap after a force jog barcode character or OMR mark is read see section Reading Specifications on page 224 for further details Autoend jog step Sets the amount the conveyor is advanced after the Autoend button is pressed 1 Select the Output Conveyor settings as required for unsorted mail or sorted mail if using a mailsort as shown below 4 Operator IMOS Settings 101 Page 101 May 29 2020 11 3...

Page 104: ...Printer Output Settings 102 Page 102 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 105: ... the column in the Flexmail database Mailshot sequential non reset Setting is the same as Mailshot sequential but if the machine is Autoended then switched back on it will continue where it left off in the database Without non reset the machine will restart at the first entry Matching Dynamic DB lookup Setting is the same as Matching DB lookup except the database is not located locally on the Flex...

Page 106: ...Lookup option The lookup column name must be the same name of the column in the Flexmail database and must not contain any spaces This is defined by the characters selected in the barcode 4 Select the Head height to be used for the size of the pack then press Ok as shown below 104 Page 104 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 107: ...5 Finally select the Dynamic head mode to either On or Off 6 Press Next once the desired settings have been made 4 Operator IMOS Settings 105 Page 105 May 29 2020 11 33 ...

Page 108: ...job number to be read from the first page being processed on the prime document channel The prime document channel is halted until inserter IMOS has confirmed with AIMS that it is a valid job and then continues processing When using the Read from prime mode the software uses the job number read for statistics and data logging Read on output 3 Enter a Job number only if Manual entry is selected as ...

Page 109: ... piece Following successful processing IMOS will report back to AIMS and AIMS will then update the database showing the outcome result for each mail piece All the information to control the inserter contained within the barcode label 2D BCR OCR This mode enables us to produce a reprint listing as we know which Mail pieces have failed Lookup In this mode Job number and Mail piece specific data is r...

Page 110: ...ave to complete defining the Job mailset Once a job has been created it can be edited if needed by pressing the Edit button for the selected job in the Jobs screen 108 Page 108 May 29 2020 11 33 4 Operator IMOS Settings ...

Page 111: ...ile Feeder Separator Adjustment 117 500 Sheet Hoppers 120 1000 Sheet Hoppers 121 Accumulator Side Guide Adjustment 124 Flex Folder Separator Adjustment 126 Curled Paper Guide Adjustment 127 CIS Reader Adjustment 129 Angled Version Default 133 In line Version 134 5 2 Fine Tuning a Job 139 Unit Fine Tuning 140 Insert Head Hopper Fine Tuning 142 Document Fine Tuning 143 CIS Reader Diagnostics 145 5 3...

Page 112: ......

Page 113: ...sed Loading the Envelope Hopper 1 Load the required envelopes needed for processing flaps forward facing into the envelope hopper as shown below 2 The conveyor will automatically move the loaded envelopes forward Adjustments to the envelope hopper side guides may be needed to suit the envelope size being processed 111 Page 111 May 29 2020 11 33 5 Operator Instructions ...

Page 114: ...ensuring the envelopes being processed are fed through correctly and centred The side guides taper towards the output exit of the conveyor Ensure the guides are adjusted at the feed end of the conveyor to ensure envelopes are fed through freely and unrestricted Adjustments to the conveyor backrest may also be needed to suit the envelope size being processed 112 Page 112 May 29 2020 11 33 5 Operato...

Page 115: ... lock the conveyor backrest into position once the desired adjustment has been made Once feeding begins the backstop should be left in its pulled back state and let the conveyor move the envelopes forward towards the pickup rollers 6 Adjust the conveyor backrest angle to suit the following envelope sizes C4 C5 Backrest angle should be fully raised for C4 and C5 sized envelopes DL DL Backrest angle...

Page 116: ...sides once the final adjustments have been made If envelopes feed erratically try adjusting the backrest angle inbetween fully raised and lowered positions Envelope Separator Adjustment The separator prevents more than one envelope being fed at a time 1 First open the Insert Head side cover 114 Page 114 May 29 2020 11 33 5 Operator Instructions ...

Page 117: ...ntil the separator will just grip the envelope Clockwise Decreases the gap Anticlockwise Increases the gap 4 Close the Insert Head side cover once the desired adjustments have been made Loading the Versatile Feeder Hopper 1 To load the Versatile Feeder hopper first insert a single document or enclosure into the hopper 5 Operator Instructions 115 Page 115 May 29 2020 11 33 ...

Page 118: ...er pocket correctly Adjustments to the Versatile Feeder hopper side guides and separator gap may be needed to suit the document or enclosure size being processed see section Versatile Feeder Separator Adjustment on page 117 3 Re tighten the thumb screw knob once the desired adjustments have been made 4 Load the remaining documents or enclosures required for processing into the hopper 116 Page 116 ...

Page 119: ...djusted ensuring the documents or enclosures being processed are fed through correctly and centred 6 Re tighten the thumb screw knob once the desired adjustments have been made Versatile Feeder Separator Adjustment Take caution when setting the separator gap as the metal separator shield tapes indicated below may become damaged if the operator pulls a document out of the hopper too aggressively 5 ...

Page 120: ...ially just grips the paper as shown below 2 Open the Versatile Feeder operator side cover and turn the pickup roller feed wheel as shown below to feed the document further into the gap to help set the separator gap 118 Page 118 May 29 2020 11 33 5 Operator Instructions ...

Page 121: ...just grip the enclosure clockwise decreases the gap and anticlockwise increases it as indicated by the markers For problematic enclosures optional feed rollers are also available see section Changing Feed Tyres and Pickup Rollers on page 180 Loading the Flex Folder Hopper The Flex Folder is fitted with pods of one 1000 Sheet or two 500 Sheet hoppers Paper orientation in the hoppers will depend upo...

Page 122: ...mm on each side of the paper The guides move in unison when being adjusted ensuring the paper forms being processed are fed through correctly and centred 2 Load the 500 Sheet hopper ensuring the stack of paper forms stack are pressed down and loaded fully forward and under the pick up rollers as shown below 120 Page 120 May 29 2020 11 33 5 Operator Instructions ...

Page 123: ... as shown below to an approximate clearance of 1 2mm on each side of the paper The guides move in unison when being adjusted ensuring the paper forms being processed are fed through correctly and centred 2 Push the tray firmly downwards all the way and load the 1000 Sheet hopper ensuring the stack of paper forms are loaded fully forward as shown below 5 Operator Instructions 121 Page 121 May 29 20...

Page 124: ...e thumb screw knob once the desired adjustments have been made Reading Orientations UK and European Document Reading Orientations US Document Reading Orientations 122 Page 122 May 29 2020 11 33 5 Operator Instructions ...

Page 125: ...Non Reading Orientations UK and European Document Non Reading Orientations US Document Non Reading Orientations 5 Operator Instructions 123 Page 123 May 29 2020 11 33 ...

Page 126: ...he pre set size markings as shown below to determine the correct size and orientation of the paper forms to be collated together before folding as a group The side guide should just cover the indicator pre set size markings The guides move in unison when being adjusted ensuring the paper forms being processed are fed through correctly and centred 3 Re tighten the thumb screw knob once the desired ...

Page 127: ...the accumulator raise the overguide until it locks up into place as shown below 5 Once complete press the lock latch inwards to release the overguide and return it into position 5 Operator Instructions 125 Page 125 May 29 2020 11 33 ...

Page 128: ... at a time The adjustment wheels for both the 500 Sheet and 1000 Sheet hoppers are located on the operator side of the Flex Folder 1 To access the separator adjustment wheels first open the Flex Folder operator side cover as shown below 126 Page 126 May 29 2020 11 33 5 Operator Instructions ...

Page 129: ...to 100gsm The separator roller should just contact the pad below Increase the gap slightly if sheets feed erratically Thicker Forms Slide a form into the gap and adjust the wheel until the separator just grips it 4 Close the Flex Folder operator side cover once the desired adjustments have been made Curled Paper Guide Adjustment 500 Sheet hoppers have curled paper guides to help eliminate in most ...

Page 130: ... left and right inside feed end of the hopper tray as shown below 3 Adjust the thumb knobs upwards or downwards using the marker indicated in image below as a visual aid to help achieve the required setting 128 Page 128 May 29 2020 11 33 5 Operator Instructions ...

Page 131: ...a Flex Folder it must be adjusted to align with the barcode label on the form being processed 1 To access the CIS Reader adjustment tabs first open the Flex Folder operator side cover as shown below 5 Operator Instructions 129 Page 129 May 29 2020 11 33 ...

Page 132: ...on and can only read portrait orientated forms documents Always position the CIS Readers for both top and bottom reader fully to left or right side Do not position the reader in between as this can cause bad read errors 3 To adjust the CIS Reader for bottom read slide the blue adjustment tab to the left or right side as shown below according to where the label is printed on the form document for t...

Page 133: ... documents and different packs or inserts of varying thickness 1 Raise the Insert Head perspex top cover to access the collate clam as shown below 2 The paper control lever can be adjust according to the following Upwards towards exit For thick packs or if lightweight prime documents are struggling to get into the collate pocket Downwards For single sheets or inserts of varying thickness The lever...

Page 134: ...ally fitted with a catch tray at the exit receiving processed envelopes in a stack to allow subsequent hand removal and can be adjusted to suit a variety of envelope sizes 1 To adjust the catch tray first loosen the thumb screw knob on the underside and side of the catch tray 2 Move the stops as required adjusting the catch tray according to the envelope size being processed as shown below 132 Pag...

Page 135: ...the size of envelopes being processed for the particular job Angled Version Default 1 To adjust the Output Conveyor backstop first loosen the thumb screw knob 2 Adjust the backstop so that the ejecting envelopes contacts the backstop plate halfway up and then falls fully onto the conveyor surface as shown below 3 Re tighten the thumb screw knob once the desired adjustments have been made 5 Operato...

Page 136: ...ully onto the surface as shown below 3 Re tighten the thumb screw knobs once the desired adjustments have been made Output Conveyor Backrest Adjustment When the envelopes reach the end of the conveyor they will stack up against the backrest which can be adjusted to suit the required amount of tilt 1 To adjust the Output Conveyor backrest first loosen the thumb screw knobs on each side 134 Page 134...

Page 137: ...ray Adjustment The Output Sorter can be optionally fitted with a catch tray at either exit receiving processed envelopes in a stack to allow subsequent hand removal and can be adjusted to suit a variety of envelope sizes 1 To adjust the catch tray first loosen the thumb screw knob on the underside of the catch tray 5 Operator Instructions 135 Page 135 May 29 2020 11 33 ...

Page 138: ... knob once the desired adjustments have been made Turner Side Guide Panel Adjustment If the job is programmed to turn the envelope the side guide panel must be lowered For all other jobs the panel must be raised 1 To adjust the side guide panel first loosen the thumb screw knobs on each end 136 Page 136 May 29 2020 11 33 5 Operator Instructions ...

Page 139: ...ent If the Turner is fitted directly to the Insert Head exit an adjustable backstop will be attached The backstop is not fitted when the Turner is fitted to an Output Sorter 1 To adjust the backstop first loosen the thumb screw knob 2 Place an envelope on the track touching the rollers inside the backstop 5 Operator Instructions 137 Page 137 May 29 2020 11 33 ...

Page 140: ...en the thumb screw knob once the desired adjustments have been made Infeed Rollers Adjustment The infeed rollers can be adjusted to provide drive onto envelopes if there are problems transferring them to the turner exit To adjust the infeed rollers simply lower one or both rollers as needed shown below 138 Page 138 May 29 2020 11 33 5 Operator Instructions ...

Page 141: ...tance 1 To access fine tuning first select a job then navigate to the Run Screen 2 Fine tuning can then be accessed by selecting the relevant unit hopper or document unit needed tuning in the Run Screen GUI as shown below Any fine tuning adjustments made will only apply to the current job selected 139 Page 139 May 29 2020 11 33 5 Operator Instructions ...

Page 142: ... GUI to open the fine tuning dialog box options 2 Press Advanced to view all available options for fine tuning the unit select as shown below Most envelopes will run at default settings as shown below only adjust if required 140 Page 140 May 29 2020 11 33 5 Operator Instructions ...

Page 143: ...he envelope Select High for thick packs or Low for single sheets or thin packs Wetting and Sealing Seal Time ms Adjusts the time ms the envelope ejects after sealing Adjust Wetter Start mm Adjusts where the wetter beam starts Select to adjust the start point towards insertion area in increments of 1mm Adjust Env Seal Pos mm Adjusts the seal position of the envelope Select to adjust the position of...

Page 144: ...al Mode Adjusts the seal mode of envelopes Select Off if manual or later hand insertion is required Deskew Adjusts the skew of documents If skewing occurs select Low if possible select High setting only if necessary Wetter Pump On Off Turns the Wetter Pump On or Off Switch pump On for few seconds if wetter tank has dried out Wetter tank will automatically refill in normal use 3 Press Ok once the d...

Page 145: ...ument on the Run Screen GUI to open the fine tuning dialog box options as shown below Options available will depend upon weather a Versatile Feeder or Flex Folder is fitted and also whether a reading unit is fitted 5 Operator Instructions 143 Page 143 May 29 2020 11 33 ...

Page 146: ... contrast printing The following options are available only if a reading unit is fitted Reset Seq Count Resets the sequence count Select this option to reset the sequence if sequence BCR OMR marks are in use and the job is disrupted Calibrate Reader Select this option following the on screen instructions to calibrate the CIS reader CIS Reader Diagnostics Select this option to display the label of ...

Page 147: ...CIS Reader Diagnostics 5 Operator Instructions 145 Page 145 May 29 2020 11 33 ...

Page 148: ...the bottom right corner of the Reader Diagnostics screen to request the following data as shown below Main Select Main to display the decoded CIS image as shown below Scope 146 Page 146 May 29 2020 11 33 5 Operator Instructions ...

Page 149: ...s against the programmed pitch of the OMR as shown below Diagnostic Data Select Diagnostic Data to display details of the last 10 most recent barcodes that were read as shown below 5 Operator Instructions 147 Page 147 May 29 2020 11 33 ...

Page 150: ...nning a matching job select Matching Data to check and display a defined field in the barcode of both the prime document and matched document or insert as shown below 148 Page 148 May 29 2020 11 33 5 Operator Instructions ...

Page 151: ...5 Operator Instructions 149 Page 149 May 29 2020 11 33 ...

Page 152: ...wn below 2 Load the machine with the correct stationery required for the selected job Ensure settings and adjustments to the machine units have been made according to the job requirement prior to running the job see section Setting up a Job on page 111 for further assistance 150 Page 150 May 29 2020 11 33 5 Operator Instructions ...

Page 153: ...stance Cascading Job Cascading allows all available hoppers to be loaded with the same document type Maximum of 2 x adjacent hoppers from Versatile Feeders Maximum of 3 x mark reading hoppers from a Flex Folder Maximum of 4 x non reading hoppers from a Flex Folder The inserting system automatically switches to the next hopper when the current active feeding hopper is empty and vice versa As shown ...

Page 154: ...section Document Mailset on page 77 for further assistance The following applies when using Cascading for a Flex Folder with a 1000 Sheet feeder not applicable to 500 Sheet feeders 1 Press the Run button while the machine is still running after reloading the empty hopper 2 Paper is then fed to pre load otherwise machine will stop with a full hopper 3 Press the Run button to continue 152 Page 152 M...

Page 155: ... using the daily mail function for the Versatile Feeder first ensure Daily Mail has been selected as the hopper feed mode in the document settings and the separator gap on the Versatile Feeder hopper is adjusted to suit the group of documents or packs being processed 1 Open the separator gap on the Versatile Feeder hopper wide enough to insert the required stationery needed for processing corner f...

Page 156: ...ion for the Flex Folder first ensure Daily Mail has been selected as the hopper feed mode in the document settings and the divert tray on the Flex Folder accumulator is attached 1 Raise the accumulator overguide to lock it into place as shown below 2 Hook the divert tray into the top surface slots of the accumulator 154 Page 154 May 29 2020 11 33 5 Operator Instructions ...

Page 157: ...gin processing and select Auto Feed or Manual Feed in the confirmation dialog box as shown below Auto Feed Pauses 1 or 2 seconds before feeding Manual Feed Pass finger over divert sensor to feed document 5 Once the machine begins running feed the daily post fully into the accumulator within 30 seconds after this press Run again 6 To disable the daily mail function navigate to the document settings...

Page 158: ...Stapling Restrictions The following staple restrictions shown below apply when using Daily Mail for both Versatile Feeder and the Flex Folder 156 Page 156 May 29 2020 11 33 5 Operator Instructions ...

Page 159: ...ng Flex Folder Sensors 168 Cleaning Output Sorter Sensors 169 Cleaning Turner Sensors 171 6 2 Clearing Paper Jams 173 Insert Head Paper Jams 173 Versatile Feeder Paper Jams 175 Flex Folder Paper Jams 176 Collate Pocket Paper Jams 174 Base Unit Paper Jams 177 Tower Unit Paper Jams 178 Accumulator Paper Jams 179 6 3 Changing Feed Tyres and Pickup Rollers 180 Insert Head Feed Tyres and Pickup Rollers...

Page 160: ......

Page 161: ...pressing the toggle switch located at the rear of the Insert Head to the off position and unplugging the mains power cable completely from the electrical power supply Cleaning Sensors The machine uses optical sensors to track the movement of mail pieces along the paper path and must be regularly cleaned to prevent false readings Optical sensors consist of the following two halves which both need t...

Page 162: ...clam for cleaning the sensors inside the collation area 2 Lift the collate clam closest to envelope hopper so it locks into place as shown below 3 Clean the envelope feed and deskew sensors as shown below looking towards the envelope hopper 160 Page 160 May 29 2020 11 33 6 Operator Maintenance ...

Page 163: ...skew sensor as shown below looking away from the envelope hopper 5 Clean the collate pocket and collate entry sensors as shown below looking away from the envelope hopper 6 Operator Maintenance 161 Page 161 May 29 2020 11 33 ...

Page 164: ...n into the collate pocket area Then lower the Collate clamshell back down into it s original position 7 Lift the Upper conveyor assembly furthest from the envelope hopper so it locks into place as shown below 162 Page 162 May 29 2020 11 33 6 Operator Maintenance ...

Page 165: ...n below 9 Lower the side cover then lift the overguide inside the closer cavity and latch it into place as shown below 10 Clean the insertion area sensors below the overguide as shown below 6 Operator Maintenance 163 Page 163 May 29 2020 11 33 ...

Page 166: ...p sensors as shown below 12 Clean the envelope hopper sensor as shown below 13 Open the side cover then lower the front output cover below the envelope feeder as shown below 164 Page 164 May 29 2020 11 33 6 Operator Maintenance ...

Page 167: ...rs 1 Raise the Insert Head perspex top cover to access the first installed Versatile Feeder station for sensor cleaning 2 For subsequent installed feeder stations open the Versatile Feeder side cover as shown below to access from the side for sensor cleaning 6 Operator Maintenance 165 Page 165 May 29 2020 11 33 ...

Page 168: ...ush the air duster nozzle approximately 30mm inside the feed hopper shown below and spray liberally to clean the sensors 5 Open the side cover and lower the conveyor track assembly as shown below 166 Page 166 May 29 2020 11 33 6 Operator Maintenance ...

Page 169: ... to access the first installed Versatile Feeder mark reading station for sensor cleaning 2 For subsequent installed feeder mark reading stations these sensors can only be accessed after dismantling by a manufacturer trained certified Engineer 3 Once dismantled clean the sensors shown below 6 Operator Maintenance 167 Page 167 May 29 2020 11 33 ...

Page 170: ... 1 Open the Flex Folder top cover as shown in Figure 6 20 to access the sensors for cleaning 2 Insert the air duster under the chassis bridges to clean the sensors shown below 168 Page 168 May 29 2020 11 33 6 Operator Maintenance ...

Page 171: ...ter is fitted with three sensors located in the positions shown below 1 Raise the Output Sorter top cover as shown below to access the sensors for cleaning 2 Clean the input sensor shown below 6 Operator Maintenance 169 Page 169 May 29 2020 11 33 ...

Page 172: ...3 Clean the output sensor shown below 4 Clean the divert sensor shown below 170 Page 170 May 29 2020 11 33 6 Operator Maintenance ...

Page 173: ...ors one located on the output side of the turn column the other is located on the output edge just before the Franker 1 Clean the turn column rotate sensor shown below 2 Clean the output sensor shown below 6 Operator Maintenance 171 Page 171 May 29 2020 11 33 ...

Page 174: ...r solvents as these may damage the belts Cleaning Rollers All rollers and feed wheels should be cleaned periodically to remove any residue picked up from processing printed material To clean the rollers and feed wheels use a lint free cloth dampened with water This method will normally be sufficient however for more stubborn soiling the use of a foam type surface cleaner may help Clean the full wi...

Page 175: ...he on screen error message within IMOS To clear any paper jams always follow the IMOS on screen instructions and the correct procedures set out below for the relating unit affected only Insert Head Paper Jams 1 Open the Insert Head side cover operator side and lower the front sealer cover as shown below 173 Page 173 May 29 2020 11 33 6 Operator Maintenance ...

Page 176: ...o view 3 Pull the jammed paper out and return the covers to their original position Collate Pocket Paper Jams 1 Raise the Insert Head perspex top cover to access the collate clam 2 Lift the collate clam closest to envelope hopper so it locks into place as shown below 174 Page 174 May 29 2020 11 33 6 Operator Maintenance ...

Page 177: ...document being processed will result in an IMOS document has failed to arrive error Versatile Feeder Paper Jams 1 Open the Versatile Feeder side cover 2 Push the levers indicated below to access the jammed paper 3 If the jammed paper is not fully visible turn the blue knobs clockwise or anticlockwise to wind it into view 4 Pull the jammed paper out and close the Versatile Feeder side cover once co...

Page 178: ...Flex Folder Paper Jams 1 To clear any paper jams in Flex Folder base or tower units first open the Flex Folder operator side cover as shown below 176 Page 176 May 29 2020 11 33 6 Operator Maintenance ...

Page 179: ...w 2 If the jammed paper is not fully visible turn the blue knobs clockwise or anticlockwise to wind it into view 3 Pull the jammed paper out and lower the transport assemblies back into their original position 4 Close the Flex Folder operator side cover once complete 6 Operator Maintenance 177 Page 177 May 29 2020 11 33 ...

Page 180: ...he jammed paper is not fully visible turn the blue knobs clockwise or anticlockwise to wind it into view 3 Pull the jammed paper out and lower the transport assembly and roller assembly back into their original position 4 Close the Flex Folder operator side cover once complete 178 Page 178 May 29 2020 11 33 6 Operator Maintenance ...

Page 181: ...ms raise the accumulator overguide until it locks up into place as shown below 2 Remove the jammed paper 3 Once complete press the lock latch inwards to release the overguide and return it into position 6 Operator Maintenance 179 Page 179 May 29 2020 11 33 ...

Page 182: ...t feeding Optional feed tyres are available and are fitted by following the procedures set out All replaceable rollers may be replaced or changed in a similar way as follows Insert Head Feed Tyres and Pickup Rollers 1 To replace the Insert Head feed tyres on the envelope tractor assembly simply slip off the tyres as shown below and replace as required 180 Page 180 May 29 2020 11 33 6 Operator Main...

Page 183: ...he Insert Head perspex top cover and lift the collate clam closest to envelope hopper so it locks into place as shown below 3 The feed pickup roller can the then be accessed under the envelope tractor assembly as shown below 6 Operator Maintenance 181 Page 181 May 29 2020 11 33 ...

Page 184: ...og is fully engaged when replaced 6 Lower the collate clam back down into it s original position and close the Insert Head Perspex top cover once replacement is complete Versatile Feeder Feed Tyres 1 Unscrew and remove the three thumb screw knobs in the feed hopper as indicated below 2 Open the side guides to their widest extent 182 Page 182 May 29 2020 11 33 6 Operator Maintenance ...

Page 185: ...eneath as shown below 4 Slide the spring loaded collar on each end of the feed shaft roller assemblies inwards to release the drive dog as shown below 5 Lift the roller assembly feed shaft upwards to remove it from the feed bed 6 Operator Maintenance 183 Page 183 May 29 2020 11 33 ...

Page 186: ...assemblies back into the feed bed ensure that the flat spot on the shaft is located on the operator side as shown below This indicates a one way clutch freewheel direction and if installed on the wrong side the shaft will rotate but the wheels will not drive 184 Page 184 May 29 2020 11 33 6 Operator Maintenance ...

Page 187: ...will depend upon the following Flex Folder pod configurations with hopper 1 always being the first uppermost hopper 2 Pod Configurations 4 x 500 Sheet hoppers hoppers numbered 1 to 4 2 x 500 Sheet hoppers plus 1 x 1000 Sheet hoppers hoppers numbered 1 to 3 2 x 1000 Sheet hoppers hoppers numbered 1 to 2 1 Pod Configurations 2 x 500 Sheet Hoppers hoppers numbered 1 to 2 1 x 1000 Sheet Hopper hopper ...

Page 188: ... assembly on the operator end inwards to release the drive dog as shown below The second image is for lower 1000 Sheet hopper The pickup roller and separator assembly are combined for the lower 1000 Sheet hopper 2 Lift the pickup roller assembly upwards to remove it from the feed bed and replace as required 186 Page 186 May 29 2020 11 33 6 Operator Maintenance ...

Page 189: ...once replacement is complete Hopper 2 3 and 4 Pickup Rollers To access the feed pickup rollers for hoppers 2 3 and 4 it is advisable to remove all hoppers for ease of access beginning with the lowermost subsequent hopper 1 Slightly lift and gently pull out the hoppers as shown below to access the feed pickup rollers for replacement 2 Follow the procedures set out in section Flex Folder Pickup Roll...

Page 190: ...e sealing fluid has been depleted Cleaning the Wetter Tank 1 Open the side cover of the Insert Head 2 Using the blue tab as shown below lift the end of the wetter tank slightly and withdraw it outwards 3 Empty the tank and clean it by running clear water over it for a few minutes 4 Replace the tank which will then be replenished automatically by the reservoir bottle 188 Page 188 May 29 2020 11 33 ...

Page 191: ...f the reservoir bottle as shown below 3 Remove the empty reservoir bottle and replace with a new one 4 Replace the pipes into the new reservoir bottle and close the Insert Head stand door For optimum sealing use only approved sealing fluid Part No 9101264H for 10 litre bottle 6 Operator Maintenance 189 Page 189 May 29 2020 11 33 ...

Page 192: ......

Page 193: ...193 7 2 Insert Head Troubleshooting 194 7 3 Versatile Feeder Troubleshooting 195 7 4 Flex Folder Troubleshooting 196 7 5 Output Conveyor Troubleshooting 197 7 6 Output Sorter Turner Troubleshooting 198 191 Page 191 Troubleshooting Guide May 29 2020 11 33 ...

Page 194: ......

Page 195: ... stationery has been loaded and that any machine adjustments have been made correctly according to the specific job being processed See section Setting up a Job on page 111 for further assistance Should persistent operating problems occur ensure all sensors have been cleaned before taking further action See section Cleaning Sensors on page 159 for further assistance If operating problems cannot be...

Page 196: ...fully closed Envelope flaps not opening Check outer fingers are narrower than the envelope by 9 10m on each side but must be wider than the insert Reduce the side clearance if necessary See section Finger Adjust on page 54 for further assistance Fingers not inserting properly Check side guide clearance set to 1mm clearance on each side Envelope skewed at insert Side guides too tight set to 1mm cle...

Page 197: ...an feed rollers and pick up rollers D Separator is set too tight E Sensors in feed area blocked or dirty Paper not picking up or not feeding properly A Separator gap set too large B Clean feed rollers and pick up rollers C Check side guide clearance set to 1mm clearance on each side D Let stationery settle for 24 hours near to machine before use E Check relative humidity should be between 30 80 Do...

Page 198: ...A Dirty fold rollers clean with damp cloth B Fold plates incorrectly set check settings See section Fold Settings on page 86 for further assistance C Change standard fold type e g C Fold instead of Z Fold or use custom fold Paper not folding correctly 196 Page 196 May 29 2020 11 33 7 Troubleshooting Guide ...

Page 199: ...it output rollers in the 2nd position to assist envelope travel Contact your local Manufacturer trained Technical Support Engineer for further assistance Envelopes travel untidily along conveyor on Angled Version Adjust the Batch complete jog step in Output Conveyor Settings See section Output Conveyor Settings on page 100 for further assistance Excessive or insufficient gap between batches when i...

Page 200: ...ailing to turn when they should A Ensure adjustable Turner side guide panel is lowered when turning envelopes See section Turner Side Guide Panel Adjustment on page 136 for further assistance B Clean the conveyor belt surface Envelopes failing to turn properly Ensure correct exit is selected in Output Placement See section Output Placement on page 96 for further assistance Envelopes ejecting from ...

Page 201: ... Head Specifications 206 8 3 Versatile Feeder Specifications 215 8 4 Flex Folder Specifications 217 8 5 Output Conveyor Specifications 221 8 6 Output Sorter Turner Specifications 222 8 7 Reading Specifications 224 199 Page 199 Technical Specifications May 29 2020 11 33 ...

Page 202: ......

Page 203: ... including furniture Versatile Feeder 535mm Length 1080mm including accumulator divert tray 565mm Width 1500mm Height including furniture Flex Folder NOTE Fitted with 4 x 500 Sheet Trays 1600mm incl backrest 420mm Width 435mm Output Conveyor 530mm Length 520mm Width 240mm Output Sorter 900mm Length 360mm Width 250mm Turner 201 Page 201 May 29 2020 11 33 8 Technical Specifications ...

Page 204: ...nd including accumulator and divert tray 36Kg unpackaged 42Kg packaged Output Conveyor 26Kg unpackaged Output Sorter 28Kg unpackaged Turner 23Kg unpackaged 24Kg packaged Furniture Short 34Kg unpackaged 36Kg packaged Furniture Long 44Kg unpackaged 46Kg packaged Furniture Conveyor 31Kg unpackaged 34Kg packaged PC Monitor Arm Fluid 202 Page 202 May 29 2020 11 33 8 Technical Specifications ...

Page 205: ... main machine input is taken as 2 hot wires 220VAC 50Hz 60Hz North America Frequency 0 85A Insert Head 0 58A Versatile Feeder 0 55A Flex Folder 0 50A Output Conveyor 2 5A Output Sorter 3 5A Turner 1 2A PC Monitor Input Current T6 3A Insert Head Fuse Rating 195 5W Insert Head 133 5W Versatile Feeder 126 5W Flex Folder 12W Output Conveyor 60W Output Sorter 84W Turner Power Consumption 8 Technical Sp...

Page 206: ...ating continuous NOTE 75dB A measured with Insert Head 3 x Versatile Feeders 1 x Flex Folder at an approx height and distance of 1 5m LAeq 8 78 0 dB A Daily noise exposure NOTE LAeq 8 is lower than the first action level required by Europe Physical Agents Noise Directive 2003 10 EC K Health Safety The Control of Noise at Work Regulations 2005 statutory instruments 2005 No 1643 If the work place su...

Page 207: ...revent rapid absorption of moisture in the material or condensation forming on the machine Failure to acclimatise the material may cause pre gumming of envelopes or otherwise impair machine performance The machine will function with humidity levels lower than 30 RH but high levels of static may be generated impairing machine performance The machine will function with humidity levels higher than 80...

Page 208: ...eceiving Tray Capacity Optional 215 filled envelopes C5 C6 Envelopes 300 filled envelopes C4 Envelopes NOTE Figures noted assume only 1 document is inserted into the envelope Monthly Volume Up to 200 000 filled envelopes per month DS 200iQ Up to 300 000 filled envelopes per month DS 600iQ Cycling Speeds DS 600iQ DS 200iQ Envelope 6 000 5 000 C65 114mm 1 x A4 Letter in C fold via Accumulator 6 000 ...

Page 209: ... 3 500 C4 324mm 1 x A4 unfolded 1 500 1 250 C4 324mm 8 x A4 unfolded 1 200 1 000 C4 324mm 10 x A4 unfolded 800 670 C4 324mm 15 x A4 unfolded NOTE Figures calculated as units per hour DS 600iQ DS 200iQ Document 12 000 7 800 Accumulation Speed A4 unfolded document NOTE Figures calculated as units per hour When feeding from a non prime hopper i e hopper not directly in front of CIS scanner accumulati...

Page 210: ...15 64 DS 200iQ All envelopes up to 10mm 25 64 DS 600iQ NOTE Max pack thickness is defined as the internal dimension of a rigid opening that a filled envelope will fall through under its own weight 208 Page 208 May 29 2020 11 33 8 Technical Specifications ...

Page 211: ...l clearance and is defined as the difference between the largest overall dimensions of the pack and the internal dimensions of the envelope as shown below The required clearances are summarised as follows Depth 6mm 1 4 Width 16mm 5 8 Pack 3mm Depth 12mm 1 2 Width 19mm 3 4 Pack 3mm to 6mm 8 Technical Specifications 209 Page 209 May 29 2020 11 33 ...

Page 212: ...210 Page 210 May 29 2020 11 33 8 Technical Specifications ...

Page 213: ... Details Envelope Weight Min 70gsm 18lbs bond Max 110gsm 28lbs bond C5 Envelopes or below Min 90gsm 24lbs bond Max 110gsm 28lbs bond Above C5 Envelopes 8 Technical Specifications 211 Page 211 May 29 2020 11 33 ...

Page 214: ... be securely glued to the top of the seam Flap crease must be pre scored to enable the envelope flap to open flat Flap length 48mm reduces the machine speed No glue seepage must be evident on the interior or exterior of the envelope Observe the envelope specifications as shown in two images below 212 Page 212 May 29 2020 11 33 8 Technical Specifications ...

Page 215: ...8 Technical Specifications 213 Page 213 May 29 2020 11 33 ...

Page 216: ...214 Page 214 May 29 2020 11 33 8 Technical Specifications ...

Page 217: ...ls Enclosure Size Min 148mm 5 Max 305mm 12 Width NOTE Min pack width for individual items is 210mm 8 Min 76mm 3 for non reading units Min 93mm 3 for reading units Max 216mm 8 Length NOTE Max suggested width difference between inserts is 32mm 1 This may be increased subject to testing If this difference is exceeded the insertion fingers will not cover the edges of the narrow insert and may cause in...

Page 218: ...flexible enough to suit path constraints Some enclosures may require special tyres Daily Mail Versatile Feeder Up to 25 sheets of 80gsm 20lbs bond Unfolded May be stapled or not Max thickness of staple 3mm with allowable staple positions as shown below 216 Page 216 May 29 2020 11 33 8 Technical Specifications ...

Page 219: ...urations of 2 pods for both DS 200iQ and DS 600iQ are shown in the following three images Single pod variations of either 1 x 1000 Sheet Hopper or 2 x 500 Sheet Hoppers are also available for the DS 200iQ only Contact your local Technical Support Engineer for further information regarding pod configurations for the Flex Folder 2 Pod Configuration 4 x 500 Sheet Hoppers 217 Page 217 May 29 2020 11 3...

Page 220: ...2 Pod Configuration 2 x 500 Sheet Hoppers 1 x 1000 Sheet Hopper 2 Pod Configuration 2 x 1000 Sheet Hoppers 218 Page 218 May 29 2020 11 33 8 Technical Specifications ...

Page 221: ...ion fingers will not cover the edges of the narrow insert and may cause insertion problems Sandwiching a narrow insert between two wider ones may resolve this problem Paper Weight 70gsm 18lbs bond Min 120gsm 32lbs bond for folded documents 2mm thick for unfolded inserts subject to testing 2 5mm thick for Daily Mail subject to testing Max Folding Capacity Up to 8 sheets of 80gsm 20lbs bond C Z or V...

Page 222: ...il Flex Folder Up to 25 sheets of 80gsm 20lbs bond Unfolded Up to 8 sheets of 80gsm 20lbs bond C Z or V Fold Up to 4 sheets of 80gsm 20lbs bond Double forward Fold May be stapled or not Max thickness of staple 3mm with allowable staple positions as shown below 220 Page 220 May 29 2020 11 33 8 Technical Specifications ...

Page 223: ...tput Conveyor Specifications 8 5 Conveyor Speed 4meters per minute Max Linear Speed controlled by Insert Head Selectable jog function for batching 221 Page 221 May 29 2020 11 33 8 Technical Specifications ...

Page 224: ... Weight NOTE C4 C5 with vertical windows will be turned Other sizes will pass unturned Compatible Franking Machines IJ 80 IJ 90 and IJ 110 FM Base Conveyor or DS 200i Output Conveyor IS 5000 and IS 6000 FM Base Conveyor or DS 200i Output Conveyor IS 5000 and IS 6000 FM Base only IS 5000 and IS 6000 FM Base Dynamic Scale Conveyor or DS 200i Output Conveyor Contact your local Technical Support Engin...

Page 225: ...s Compatible C4 envelope windows shown below are suitable for use on a Turner Envelope turning is determined by the address position selected when programming the job 8 Technical Specifications 223 Page 223 May 29 2020 11 33 ...

Page 226: ...ers It consists of a full portrait paper width unit capable of reading Barcodes 1D 2D and OMR marks 1 track 2 track with a maximum scanning width of 216mm Consult the Reading Specification on page 224 manual for a more comprehensive guide to reading Barcodes and OMR marks 224 Page 224 May 29 2020 11 33 8 Technical Specifications ...

Page 227: ...Disposal Instructions 9 9 1 End of Life 227 225 Page 225 Disposal Instructions May 29 2020 11 33 ...

Page 228: ......

Page 229: ...l waste and electronic equipment need 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 In order to facilitate collection and treatment separated from normal domestic waste electrical and electronic equipment is marked with the following WEEE Directive logo Do not mix with normal domesti...

Page 230: ...1 153 154 185 196 201 217 G Generate 28 34 H Hopper 14 127 151 153 154 185 206 215 217 I installation 1 5 157 J Jams 173 L languages 28 31 M Menu 23 28 37 57 Monitor 13 201 N Normal 227 O OFF 7 23 47 54 197 Operator 15 47 50 51 52 54 57 96 117 P Power 7 8 44 159 201 R Rollers 133 138 159 172 180 185 187 194 195 196 197 S Sensors 38 39 159 169 171 193 195 201 Side guide 136 194 195 198 Standard 196...

Page 231: ... Index Page 229 May 29 2020 11 33 ...

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