Accufast XL User manual

l
11/97 rev 2
labtJIIJr
Operating Manual
YOUR ACCUFAST XL IS COVERED UNDER WARRANTY
BY THE DEALERSHIP FROM WHICH YOU PURCHASED
IT. IF YOU HAVE
ANY QUESTIONS ABOUT YOUR XL,
ITS WARRANTY,
OR YOUR AUTHORIZED ACCUFAST
DEALER, SIMPLY
CALL 800-447-9990.
25-0032-00

ACCUFAST® XL Labeler
Operating Manual
TABLE OF CONTENTS
1. INTRODUCTION...............................................................................................1
1.1 ORGANIZATION
OF THIS OPERATING MANUAL .... .......... ....... .......... ..... ...... .... . .... ....1
1.2 FCC STATEMENT ......... ........... ....... .... .. ........ ....... .......... .. . ..... .. ...... .. ..................1
1.3 XL DESCRIPTION ..... ... ..... .......... ... ...... . .. . ....... ........ ....... ..... .... ..... ... ..... ........... .... 1
1.4 ITEMS INCLUDED ................ ...
..... ...... .. . ......... ...... .. ...... .. ..... ........ ......... ... ............. 2
1.5 OPERATING MANUAL SAFETY TERMS ........ .. ..... ....................... ...... ............. ........ .4
1.6 SAFETY PRECAUTIONS .... ........ . ..... .. ............. ..... .... ....... .... ..... ..... ........................5
1.7 OPERATING MANUAL TERMS... ....... .......... ...... .... .. ..... ... .... ..... .... ..... .....................6
1.8
WARRANTY ...... ..... . ...... ... ..... ... ....... .... .. ..... . ......... ..... ..... .. ...... .... ..... .... ........... .... 7
1.9 COPYRIGHTS & TRADEMARKS..........
.. ...... ....... ............. .... .......... ..... ...... ..... .........7
1.10 ORDERING ADDITIONAL EQUIPMENT ..... ............... ... ...... .. ....... ..... ... ...... . ............. 8
2. SPECIFICATIONS & REQUIREMENTS...........................................................9
2.1 SPECIFICATIONS
........ ... ..... . ....... ... . ..... ....... ...... ...... .................................. ....... ...9
2.2 OPERATING REQUIREMENTS............ ......... . .......... . ....... ... ...... .... ................. .........9
3. POWER CONNECTION..................................................................................10
3.1 SAFETY ......... . ............ .. ........ . ...... ... .......... .. ....... ....... .... ...... ..... .... .... .............. ..10
3.2 LINE VOLTAGE.... ........ ................. ..... ........ . ...... ... ....... ...... . ....... .... .... ..... .. .........10
3.3 LINE FUSES.............. ..... ........... ....... .... ...... ........ ....... .... ................... ..... ... ...... ..12
3.4
POWER CORD ..... . ..... ..... .......... .... ...... ... ...... . ....... .... .... ....... .... ..... ..... ....... ........ 13
4.
ASSEMBLY .................................................................................................... 14
5. CONTROLS....................................................................................................17
5.1 FEED ...........
......... ..... ...... ....... .... ..... ......... ....... . ........ ... .... .. ..... ..... .. ...... . .... ......17
5.2 SPEED .
..... ... ....... ......... . .... ..... ............. ............. ..... ..... . ..... ........ ........ .. ...... .......17
5.3 LABEL..
..... ... .......... . .. ........ ....... .... .... ..........········· ······ ····· .. ....... .... ..... .. ........ .....18
5.4 LABEL POSITION 1 &2 ...............................
.. ....... .. ............ ... .. .. ..... ... ........... ... .. 18
5.5 LABEL READY....... ...... ... ........ . ..... ................. ..... ........... .... ... ..... .. ...... ....... ...... .. 18
5.6
LCD .... ........ .... . ..... . ....... ....... ..... ..... ...... .. . ..... ...... ...... .................... ..... . .... ...... .. 18
5. 7 MISSING LABEL. ...... .................... ... ..... ..... ..................... ...... .. ..... .... .. ........ ........ 18
5.8
MOVE LABEL LEAD I TRAIL . ..... .. ......... .... ..... ....... ......... .... ....... .. .... .... ............ ....19
5.9 PIECE READY ..... .. .......... ..... . ..... .... ...... ......... ...... ........ .. ....... .......... ....... . .......... 19
5.10 RESET COUNTER .... .............. ......... .. ................. .. ....... ... .... .... ............ ...... . ...... 19
5. 11 RUN/THREAD KNOB .......... ....... .... ..... ....... ............ ..... .. ... ..... .. .................. .. .....20
5.12 TRAY HEIGHT ADJUSTMENT KNOB. .......... ....... ........ .... .. .......... ....... ......... . ..... ...20
6. HIDDEN CONTROLS .....................................................................................
21
6.1 METRIC UNITS ..... ........ ....... . ...... .. ...... . ..... ........ ...... .......... ................. ...... ......... 21
6.2 ENGLISH UNITS ...... .... ..... ... ................ ......... ..... .... ..... ......... .. ....... ....... ..... ....... . 21
6.3 ABOUT XL .............. ........ ............ .. ........ ........ .......... ........ ......... .. .......... ... .. . ..... .22
11/97 rev 2

ACCUFAST®XL Labeler
Operating Manual
7. OPERATION...................................................................................................23
701 THREADING LABELS 00000 0 000 0000 00 0 00000 0 00000000 000 00000000000000 0 0000000 00 000 000 000 0000 00000 000 00000 000 00023
702 PROGRAMMING LABEL POSITION o ooo o oo oo oooooo oo oo o oo oooooooooooooo oooooooo ooooo o ooo oo o oooooo oooo ooooo 25
703 FEEDING MAIL PIECES oooo oooooo o oo o oo o oo o ooo o oo oo oooooooo0oo000 oooo 0000000000000 0 0000 00 00 00 00 0 00 000000 00 00 25
704 APPLYING LABELSOOOOOoOO OOOo O OO O OOOO OO OO oO ooOo O oo0000 0 00 00000000000000 00000 000 0 00000000000 0 00000000000 00 0000 28
705 STOP LABELING ooooooooooooo oo ooooo oooooo ooo ooo o oo oooo o ooooooooooooooooo o oo oo ooo ooooooooo ooo o ooooo oooooo 0o o0oo 28
706 RESUME LABELING oo oo ooooooooooooooooooooooooooooooo oo ooooooooooooooooo ooo ooo o ooooooooo oo oooooo oo o oo ooo ooo o 29
7 07 SPLICING LABELS 0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 029
708 ZIP CODE ® SORTING o oo o oooooooooooooooooo oo oo o ooo ooo o ooooooooooooo oo oo ooooo Oo oo OOO o OoOo000 0 00 00000000 0000030
8. LCD MESSAGES............................................................................................ 31
8 01 LABEL IS MISSING Ooooo oooooooooo oo oo o oooooo o oo o ooooooooooooooO OO oooooo ooo ooo ooooo O oooo oo o ooOo OOOo000 00 0000 00031
8 02
POSITION LABEL ON MAIL PIECEooooooooooooooooooooooooooo o ooooo o oooooooooooooo oooo ooooooo ooo ooo ooo oo o 31
803 LABEL TAKE-UP SPOOL Is FULL.oooooooooooooo o oooo oooooooo ooo oo oo oooooo oo ooooo ooo oo ooo0o 0o 00000000 00003 1
804 FEEDER JAM o oooo oo oo ooooo oooooooooooooooooooooo oo o oo oo o ooooo o oooo oo ooo o ooooooo oo o ooooooooo ooooooo oo o00 ooo 00 0 00 32
805 TRANSPORT JAM ooo ooooooooo ooo oo oooooooooooooooooooo o ooo o oooo oooooo oooooo 00o00000000000 0000 00 000 00000000000 0 32
9. MAINTENANCE..............................................................................................34
9 01 CLEANING oo ooo ooooo oo oooooooo oooo ooooo oo oooooo oo oo oooo o ooooooooooooooo oo ooooooooo o oooooo ooo o ooo oo0 o0 000 00 00 00 000 34
10. TROUBLESHOOTING..................................................................................38
10 01 TROUBLESHOOTING CHART o oo oooo oo oo oooo oo ooooooooooooo OOoOOo 000 0 0000 00 0 00000000 00 0 000000000 00000 0 000 38
11. SERVICE ...................................................................................................... 41
1101 SERVICE 000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000041
11 02 REPACKING INSTRUCTIONS 0000000000000000000000 00 0000000000000000000000000000000000000000 00 0000000000 .41
ii
rev 2 11/97

1. INTRODUCTION
1.1 Organization of
this Operating
Manual
1.2 FCC Statement
1.3 XL Description
11/97 rev 2
ACCUFAST® XL Labeler
Operating Manual
This manual starts with a description of your XL, then
describes its set up, operation and maintenance. Finally,
information is offered to help you determine what can
go
wrong and what to do about it. There are many helpful tips
along the way, and it is strongly suggested that you become
familiar with this entire manual prior to operating the XL.
This equipment has been tested and found to comply with
the limits for Class A digital device pursuant to Part
15 of
FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when
this equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio
frequency energy and,
if not installed and used in
accordance with the instructions in this manual, may cause
harmful interference to radio communications. Operation
of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required
to correct the interference at his/her own expense.
The XL is an automatic labeling machine that applies
1-up pressure-sensitive labels to mail pieces. Unlabeled
mail pieces are stacked in the feed tray. Two paper guides
hold this stack in position as the mail pieces are fed through
the XL. A
fe ed wedge improves the feeding of certain
types
of mail pieces.
The stack is separated into single pieces by separators and
feed rolls which feed the mail pieces into the XL. A
photosensor (electric eye) in the base sees each mail piece
and transmits information to the microprocessor which
controls the XL.
1

ACCUFAST® XL Labeler
Operating Manual
1.4 Items Included
When the photosensor sees a mail piece, the
microprocessor waits for the programmed delay, then
directs the label feed motor to advance the labels. A second
photosensor sees the end
of the label and signals the
microprocessor to stop advancing labels.
As the label strip exits between the label door and the label
chute, the peel bar peels the label from the backing paper.
At this point, the mail piece contacts the label and the press
roll presses the label onto the mail piece. The labeled mail
piece exits the XL, usually onto an ACCUFAST Catch
Tray or 3FV Conveyor.
The following items are shipped separately in two boxes.
Take note
of each as you unpack both boxes. (Refer to
Figure 1.1.)
smaller box
• ACCUFAST XL Head
larger box
• ACCUFAST XL Base
• Feed Wedge
• Press Roll
• Take-Up Spool with Clip
• Power Cord
• XL Operating Manual
2 rev 2 11/97

11/97 rev 2
LABEL TRAY EXTENSION
LABEL TRAY -
LABEL GUIDE BAR \ \
LABEL CHUTE ---._ \
LABEL GUIDES
LABEL DOOR
PRESS ROLL
PRESS ROLL
LATCH
ACCESS PANEL
OUTPUT ROLL
TRANSPORT BELTS
TRANSPORT SHAFTS
ACCUFAST® XL Labeler
Operating Manual
TAKE-UP SPOOL
I CLIP
RUN(THREAD KNOB
POWER CORD
/ FEEDWEDGE
>::£~ PAPER GUIDE
ADJUSTMENT KNOB
PAPER GUIDE
FEED TRAY
"------ PADDLE WHEEL
LCD
Figure 1.1-- The ACCUFAST XL, Exploded View
CAlJ" Bi ON
DO NOT LIFT OR MOVE THE XL BY ITS HEAD.
ONLY Llt;J
OR MOVE, JHE XL BY ITS BASE.
3

ACCUFAST® XL Labeler
Operating Manual
1.5 Operating
4
Manual Safety
Terms
The following highlighted blocks are used throughout this
manual to emphasize important information.
Pay careful
attention to this information.
t: CAUTIO.N Mk
t- ~$;;
ALERTS YOU TQ ; r AGJIQN~
1
~HICH MAY CAUSE
LOSS OF
MA . :(: ,fERIALS (MAIL PIECES AND
LABELS)
OR wDAMAGE TO EQUIPMENT.
NOTE
Draws your attention to an important statement or
action.
--------------------------·
I TIP I
I I
1 A
suggestion to enhance the XL's productivity. 1
-- - - -~- - ---· - ' - __ ., _ ,_, __ ____ _ ----- - - - -'·-- - - - - - - -
rev 2 11/97

1.6 Safety
Precautions
11/97 rev 2
ACCUFAST®XL Labeler
Operating Manual
Observe the following safety precautions and warnings
when operating, cleaning or repairing the XL. Failure to do
so may result in physical injury ordamage to the XL. The
manufacturer assumes no liability for your failure to
comply with these requirements.
5

ACCUFAST® XL Labeler
Operating Manual
1.7 Operating
Manual Terms
6
The following terms are used throughout this manual:
operator side
non-operator
side
rear
front
leading edge
trailing edge
backing paper
leader
side of XL where the controls are
located
opposite the operator side
input end
output end
edge
of mail pieces that enters and
exits the XL first
edge
of mail pieces that enters and
exits the XL last
paper holding the labels on the label
strip
leading portion
of the label strip with
the labels removed
application point point where the label is applied to
the mail piece
rev 2 11/97

1.8 Warranty
1.9 Copyrights &
Trademarks
11/97 rev 2
ACCUFAST® XL Labeler
Operating Manual
NOTE
Your ACCUFAST XL is covered under warranty by
the dealership from which you purchased it. If
you have any questions about the XL, its
warranty, or your authorized ACCUFAST dealer,
simply call 800-447-9990.
AUTOMECHA Mfg. warrants your ACCUFAST XL
against defects in materials and workmanship for a period
of six months from the original ship date when used in
accordance with the operating instructions in this manual.
This warranty covers the cost
of parts when the machine is
presented by its original purchaser to an authorized
ACCUFAST Service Center. Should warranty repairs
become necessary, the service provider, at his/her option,
will repair or replace such parts required to restore the XL
to serviceable condition.
This warranty does not cover consumable parts such as
belts, rollers and sweeps used to contact and transport mail
pieces and tabs. This warranty does not extend to
incidental or consequential damages arising out
of a
warranty claim, or to costs associated with maintenance of
the equipment. This warranty does not cover damages
resulting from shipping, accident, misuse, abuse, neglect,
mishandling, alteration or modification. Your rights under
this warranty may vary from state to state. Contact
AUTOMECHA Mfg. at 800-362-5734 should difficulties
arise with any warranty claim.
Copyright 1997 by AUTOMECHA Ltd. All rights
reserved. ACCUFAST is a registered trademark
of
AUTOMECHA Ltd. This publication is protected by U. S.
copyright law. No part of this publication may be copied,
transferred or distributed without the express written
permission
of AUTOMECHA Ltd.
7

ACCUFAST® XL Labeler
Operating Manual
1.10 Ordering
Additional
Equipment
8
ACCUFAST 3FV
CON VEYOR
To order, or find out about, additional ACCUF AST
equipment, contact an authorized ACCUF AST dealer. To
locate
an authorized dealer in your area, call ASMARC at
800-447-9990.
ACCUFAST 3FV
STAND
ACCUFASTXL
LABELER
ACCUFAST
SLIDING STAND
ACCUFAST KT 2
TABBER
Figure 1.2 -- In-line labeling, tabbing & sorting with
ACCUFAST Equipment.
rev 2 11/97

ACCUFAST® XL Labeler
Operating Manual
2. SPECIFICATIONS & REQUIREMENTS
2.1 Specifications
2.2 Operating
Requirements
11/97 rev 2
Size
20
11
1X 16
11
h X 21 II w
Weight
69 lb. assembled
Power
Possible line voltages are 240V, 230V, 220V, 120V,
and 1
OOV at 50-60 Hz
Mail Piece Size
Length: 3
11
minimum, 14
11
maximum
Width: 41/2
11
minimum, 16
11
maximum
Mail Piece Thickness
Minimum: single sheet
of20 lb. bond paper tri-folded
Maximum: 1/4
11
Label Size
Length:
Width:
Space:
15
/
11
minimum 4
11
maximum
16 '
23/8
11
minimum, 6
11
maximum
There must be some space between labels on
the backing paper)
Label Position Accuracy
±1/16
11
guaranteed when using non-expired labels
designed for machine application
Production
up to
15 ,000 mail pieces per hour (based on #10
envelope)
9

ACCUFAST® XL Labeler
Operating Manual
3. POWER CONNECTION
3.1 Safety
3.2 Line Voltage
10
The XL can connect to any power distribution system,
including the European IT Power System. Because the
European IT Power System does not have a grounded
neutral leg, the XL uses protective fusing in both the
neutral and hot supply lines
of power.
The XL is rated for continuous operation using a variety
of
supply voltages. Possible line voltages are 240V, 220V,
120V and
lOOV at 50 or 60Hz. The manufacturer
configures the XL to operate with the voltage requested by
the customer.
Read the current voltage setting through the VOLTAGE
SELECTOR WINDOW on the non-operator side
of the XL.
(Refer to Figure 3.1.) Use the following instructions to
change the voltage setting:
rev 2 11/97

11/97 rev 2
ACCUFAST® XL Labeler
Operating Manual
NOTE
The detachable POWER·CORD may have to be
chang~d .to match the particular power-source
output.
1. Unplug the POWER CORD.
2. Use a small screwdriver or similar tool to push up on
and release the FUSE DRAWER LOCKING TAB.
3. Pull the FUSE DRAWER out of the POWER ENTRY
CASING.
4. Pull the VOLTAGE SELECTOR out ofthe FUSE
DRAWER.
5. Rotate the VOLTAGE SELECTOR until the correct
voltage is on the same side as the VOLTAGE
SELECTOR WINDOW.
6. Place the VOLTAGE SELECTOR in the FUSE
DRAWER and verify the correct voltage selection.
7. Place the FUSE DRAWER in the POWER ENTRY
CASING.
POWER ENTRY
CASING
/ FUSE
/ VOLTAGE
// SELECTOR
r- FUSE DRAWER
//
/
VOLTAGE
SELECTOR
APPLIANCE INLET
~,,)._ '"""""' / WINDOW
~ POWER CORD
FUSE DRAWER
LOCKING TAB
Figure 3.1 --Power Connection
11

ACCUFAST® XL Labeler
Operating Manual
3.3 Line Fuses
12
The FUSE DRAWER located on the non-operator side
contains two LINE FUSES. (Refer to Figure 3.1.) The
neutral and hot lines
of power are fused. Both LINE
FUSES must be intact for the XL to operate properly.
Use the following instructions to verify that the LINE
FUSES installed have the proper fuse value or to replace a
blown fuse:
1. Unplug the POWER CORD.
2. Use a small screwdriver or similar tool to push up on
and release the FUSE DRAWER LOCKING TAB.
3. Pull the FUSE DRAWER out of the POWER ENTRY
CASING. The LINE FUSES are inside.
4. Determine the proper fuse value as well as the condition
of the LINE FUSE. The fuse value is shown on the
metal tip
of the LINE FUSE. The chart below lists the
selected voltage in the left column followed by the
proper fuse value in the right column.
Selected Voltage Fuse Value
1
OOV ............................2.0A (250V time delay)
120V ............................2.0A (250V time delay)
220V ............................1.0A (250V time delay)
240V (or 230V).............1.0A (250V time delay)
5. Replace the LINE FUSE if necessary. Both LINE
FUSES must be intact for the XL to operate properly.
6. Install the FUSE DRAWER in the POWER ENTRY
CASING.
rev 2 11/97

3.4 Power Cord
11/97 rev 2
ACCUFAST® XL Labeler
Operating Manual
The XL comes with a three-wire POWER CORD. The
POWER CORD grounds the XL when connected to an
approved three-contact electrical outlet.
1. Plug the POWER CORD into the APPLIANCE INLET
on the non-operator side. (Refer to Figure 3.4.)
2. Plug the POWER CORD into a grounded outlet.
13

ACCUFAST® XL Labeler
Operating Manual
4. ASSEMBLY
14
1. Unscrew and save the four SHIPPING KNOBS
fastened underneath the BASE. (Refer to Figure 4.1.)
A colored tab is placed on each SHIPPING KNOB.
These knobs prevent FEED TRAY movement during
shipping. If you need to ship your XL, lower the FEED
TRAY as far it allows, and screw in the SHIPPING
KNOBS.
NOTE
The XL will not operate until the SHIPPING
KNOBS are removed.
TRANSPORT SHAFTS
HEAD SUPPORT
BRACKET
SHIPPING KNOBS (4 TOTAL)
HEAD SUPPORT
BRACKET
INSERT LOWER
HOOKS
ON HEAD INTO SLOTS
Figure 4.1 -- Attaching Head to Base
rev 2 11/97

11/97 rev 2
ACCUFAST® XL Labeler
Operating Manual
LABEL TRA Y EXTENSION
LABEL TRAY "'
LABEL GUIDE BAR '\
LABEL CHUTE
HEAD
RUN!THREAD KNOB
POWER CORD
LABEL GUIDES
FEED WEDGE
PRESS ROLL
PRESS ROLL
LATCH
PAPER GUIDE
ADJUSTMENT KNOB
PAPER GUIDE
ACCESS PANEL
BASE
CONTROL PANEL
OUTPUT ROLL
PADDLE WHEEL
TRANSPORT BELTS
LCD
TRANSPORT SHAFTS
Figure 4.2 -- XL Components
2. Attach the HEAD to the BASE by sliding the two lower
hooks on the rear
of the HEAD into the two SLOTS on
the BASE. (Refer to Figures 4.1 & 4.2.) This will
align the male and female halves
of the CONNECTOR.
The CONNECTOR electronically links the HEAD and
the BASE.
3. The two plastic guides on the bottom of the HEAD
allow the HEAD to slide from side to side on the
BASE.
4. Place the FEED WEDGE on the FEED TRAY. (Refer
to Figure 4.2.)
" c!fu-Frof4
DO NOT PeACE THE FEED WEDGE VERY CLOSE
TO FEED ROLLS OR THE PADDLE WHEEL.
15

ACCUFAST® XL Labeler
Operating Manual
16
5. Place the TAKE-UP SPOOL in the HEAD. (Refer to
Figure 4.3.) Place the gear end ofthe TAKE-UP
SPOOL in the hole above the gear in one HEAD side
frame. Slide the other end ofthe TAKE-UP SPOOL
into the slot in the opposite HEAD side frame.
6. Attach the CLIP to the TAKE-UP SPOOL.
7. Lift the PRESS ROLL LATCHES and place the PRESS
ROLL in the two slots under the PRESS ROLL
LATCHES. (Refer to Figure 4.3.)
NOTE
All c~mponents must be in place for the XL to
operate properly.
LABEL TRAY EXTENSION
LABEL
TRAY ~
LABEL GUIDE BAR
LABEL CHUTE
HEAD
LABEL GUIDES
LABEL DOOR
~ /
PRESSROLL /
TAKE-UP SPOOL
~ PRESSROLL
LATCH
Figure 4.3 --XL Head Components
RUN!THREAD KNOB
rev 2 11/97